UNIT 2 – BASIC DATA COLLECTION AND ANALYSIS TOOLS

OVERVIEW

A good methods engineering program will follow an orderly process, starting from the
selection of the project and ending with the implementation of the project. The first, and perhaps
most crucial, step—whether designing a new work center or improving an existing operation—is
the identification of the problem in a clear and logical form. This unit provides a variety of such
problem-solving tools and its specific applications.

LEARNING OBJECTIVES

At the end of this unit, the students are expected to

1. Understand the basic data collection and analysis tools for process improvement
2. Apply the data collection and analysis tools to problem solving
DISCUSSION

Data collection and analysis tools are defined as a series of charts, maps, and diagrams
designed to collect, interpret, and present data for a wide range of applications and industries.
Various programs and methodologies have been developed for use in nearly any industry,
ranging from manufacturing and quality assurance to research groups and data collection
companies.

1. Pareto Analysis
In Pareto analysis, items of interest are identified and measured on a common scale and
then are ordered in descending order, as a cumulative distribution. Typically, 20 percent of the
ranked items account for 80 percent or more of the total activity; consequently, the technique is
sometimes called the 80-20 rule. For example, 80 percent of the total inventory is found in only
20 percent of the inventory items, or 20 percent of the jobs account for approximately 80 percent
of the accidents (Figure 2.1), or 20 percent of the jobs account for 80 percent of the workers’
compensation costs. Conceptually, the methods analyst concentrates the greatest effort on the
few jobs that produce most of the problems.

2. Fish Diagrams
Fish diagrams, also known as cause-and-effect diagrams, were developed by Ishikawa in
the early 1950s while he was working on a quality control project for Kawasaki Steel Company.
The method consists of defining an occurrence of a typically undesirable event or problem, that
is, the effect, as the “fish head” and then identifying contributing factors, that is, the causes, as
“fish bones” attached to a backbone and the fish head. The principal causes are typically
subdivided into five or six major categories—the human, machines, methods, materials,
environmental, administrative—each of which is further subdivided into sub-causes.
The process is continued until all possible causes are listed. A good diagram will have
several levels of bones and will provide a very good overview of a problem and its contributing
 Basic Data Collection and Analysis Tools

factors. The factors are then critically analyzed in terms of their probable contribution to the
overall problem. Hopefully, this process will also tend to identify potential solutions. An
example of a fish diagram used to identify operator health complaints in a cutoff operation is
shown in Figure 2.2.

Figure 2.1 : Pareto distribution of industrial accidents.

Twenty percent of job codes (CUP and ABY) cause
approximately 80 percent of accidents.

3. Histogram

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Histogram is a statistical graph consisting of bars representing different members of a

population, in which the length of each bar indicates the frequency or relative frequency of each
member. A useful tool because the analyst can quickly visualize the features of the data, such as:
– Shape of the distribution
– Any central tendency in the distribution
– Approximations of the mean and mode
– Amount of scatter in the data

Figure 2.3: Histogram of Quality Defects

4. Graphs
Graphs are simple tools for organizing, summarizing and visual display of statistical data. It
shows information quickly without looking at the actual data.
Circle Graph (Pie Chart): To show the percentage contribution of the elements of a
population

Bar Graph: When displaying discrete quantities rather than continuing change; or when
consistent ordering of bars is wanted (as opposed to Pareto)

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Line Graph: To show changes across time; when measuring several different items, to
show how they change relative to one another; when measuring progress towards a goal,
to show the relative improvement

5. Check Sheet
A manual data gathering and data organizing tool. Check sheet is used when
 data is to be recorded manually while ensuring that it is accurate and is easy to use later,
either for direct interpretation or for transcription
 recording involves counting, classifying, checking or locating
 it is useful to check each measurement as it is recorded, for example that it is within
normal bounds
 it is useful to see the distribution of measures as they are built up

Figure 2.3: Telephone Interruptions check sheet

6. Defect Concentration Diagram

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Defect Concentration Diagram is a drawing of the product (all relevant views), onto
which the locations and frequencies of various defect types are added. This is useful for
analyzing the causes of product or part defects and. By analyzing the defect types and
corresponding locations, the underlying causes of the defects can possibly be identified. An
example defect concentration diagram is shown below.

7. Scatter Diagrams
Scatter diagram is a graph that shows the strength of relationship between two sets of
variables, say x and y. The relationship is expressed in terms of correlation. Scatter diagrams are
used when,

 it is suspected that the variation of two items is connected in some way, to show any
actual correlation between the two
 it is suspected that one item may be causing another, to build evidence for the connection
between the two
 To be used only when both items being measured can be measured together, in pairs

Scatter Diagrams Patterns

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SUMMARY
The data collection and analysis techniques discussed in this module are used by
scientists, engineers, mathematicians, and statisticians. Most of them are statistical charting tools
used to record and/or exhibit data so that it can be interpreted more readily. The techniques also
have value for analysis. Pareto analyses and fish diagrams are used to select a critical operation
and to identify the root causes and contributing factors leading to the problem. Histogram is a
useful statistical tool that enables the analyst to quickly visualize the features of a complete set of
data. Graphs are used for organizing, summarizing and visual display of statistical data and it
shows information quickly without looking at the actual data. Check sheet is a data gathering
tool generally used in the preliminary stages of the study of a problem. Defect concentration
diagram is a drawing of the product (or other item of interest), with all relevant views
displayed, onto which the various types of defects or other problems of interest have been
sketched at the locations where they each occurred. By analyzing the defect types and
corresponding locations, it may be possible the identify the underlying causes of the defects.
Scatter diagram is useful to identify a possible relationship that exists between two process
variables.

PROBLEMS
1. Enumerate the 7 basic data collection and analysis tools and explain how each tool is
used for process improvement.
2. A factory has 10 departments, all of which have quality problems leading to delays in
shipping products to customers. A breakdown of the number of quality problems for each
department is as follows: 1) assembly, 16; 2) final packaging, 9; 3)finishing, 37; 4)
forging, 73; 5) foundry, 362; 6) machine shop, 294; 7) plastic molding, 120; 8)receiving
inspection, 124; 9) sheet metalworking, 86; and 10) tool-making, 42.
a) Construct a Pareto chart for this data.
b) Assuming that all quality problems are of equal value, in which department would
you start to take corrective action to reduce the quality problems?
c) Determine the percentage of total quality problems that are attributable to the two
departments (20% of the departments) with the most quality problems.
3. You are the marketing director of XZY automotive, a new Scottish company. You have
organized a local survey to rate your car against other small cars. 30 people were polled
and the results are shown below.
Xzy, ka, Clio, Clio, ka, fiesta, xzy, ka, 206, xzy, fiesta, fiesta, xzy, polo, fiesta, 206, 206,
polo, 206, fiesta, fiesta, fiesta, polo, xzy, polo, fiesta, xzy, xzy, ka, xzy.
You recognize the power that graphs produce. And you have decided to Graph the results
as part of your marketing drive. Explain your choice of graph.
4. Consider some process or procedure with which you are familiar that manifests some
chronic problem. Develop a cause and effect diagram that identifies thee possible causes
of the problem.
REFERENCES

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Groover, M. P. (2007). Work Systems and the Methods, Measurement and Management of Work.
Pearson Education International.
Niebel, A. F. (2009). Niebel's Methods, Standards, & Work Design (12 ed.). McGraw Hill.

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