ANALYTICS TRAINING MODULES

SERIES-B:
BASIC PROBLEM SOLVING TOOLS

Module B-02 : AFFINITY DIAGRAM

Doc. No. B-02.00.20210308
Revision 00; 8th March 2021
Authors: Pankaj Lochan / Soumeek Das

For further clarifications, write to

pankaj.lochan@jindalsteel.com / soumeek.das@jindalsteel.com © Jindal Steel & Power Ltd. All rights reserved.
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ANALYTICS TRAINING MODULES
Series A Series C Series D Series F
Basic Problem Solving Tools Management Systems Productivity & Efficiency Tools Advanced Statistical Tools
A-01 Flow Charts C-01 Quality Mgmt. Basics D-01 Value Stream Mapping (VSM) F-01 Sampling & Distribution
A-02 Cause & Effects Diagram C-02 Basic Statistics D-02 Time & Motion Study F-02 Hypothesis Testing
A-03 Stratification C-03 Statistical Process Control D-03 SMED F-03 Regression
A-04 Scatter Diagram C-04 KPI Drill Down D-04 Wrench Time Analysis F-04 Basics of DoE
A-05 Control Charts C-05 KPI Benchmarking D-05 Queuing Theory F-05 Factorial DoE
A-06 Check Sheets C-06 KPI Target Setting D-06 Inventory Management F-06 Principal Component Analysis
A-07 Histogram C-07 Strategic Analysis Tools-1 D-07 Linear Programming Problem F-07 Cluster Analysis
A-08 Pareto Charts C-08 Strategic Analysis Tools-2 D-08 Game Theory F-08 Conjoint Analysis
A-09 Graphs C-09 Strategy Management
D-09 OEE F-09 Discriminant Analysis
C-10 Daily Mgmt. in Operations
D-10 PERT & CPM F-10 Factor Analysis
C-11 Daily Mgmt. in Maint.-1
Series B D-11 Capacity & Bottlenecks F-11 Response Surface Method
C-12 Daily Mgmt. in Maint.-2
Basic Management Tools D-12 Theory of Constraints F-12 Taguchi DoE
C-13 Daily Mgmt. in Services
C-14 Cross Functional Mgmt. F-13 Weibull Analysis
B-01 Brainstorming Series E
B-02 Affinity Diagram C-15 Quality Assurance Basics
C-16 MSA Decision-making Tools
B-03 Arrow Diagram
C-17 PFD, FMEA, Control Plan E-01 Quality Function Deployment
B-04 Tree Diagram
C-18 Improvement Fundamentals E-02 Fault Tree Analysis
B-05 PDPC
C-19 5S E-03 AHP & Paired Analysis
B-06 Matrix Diagram
C-20 Quality Circles E-04 Pugh Matrix
B-07 Matrix Data Analysis
C-21 QC Story Approach
B-08 Relation Diagram E-05 Time Motion Series
C-22 Kaizen, OPL, Poka Yoke

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FLOW OF THE TRAINING DOCUMENT

1.
Introduction to Affinity
Diagram

Steps to construct Affinity

2. Diagram

Examples of Affinity
3. diagram

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AFFINITY DIAGRAM: AN INTRODUCTION

What is Affinity Diagram?

Affinity diagram is a tool that gathers large amounts of language data (ideas, opinions, issues) and
organizes them into groupings based on their natural relationships.

When to Use: Purpose & Applicability of Tool:

 Exploring in to unknown areas
 Unifying thinking of diverse group of people
 When facts or thoughts are not clear
 For gathering large amount of disorganized,
confused and intertwined verbal data.
 For organizing the verbal data into groups based
on natural relationship.
 It Discovers the previously unseen connections
between various ideas or information.

The affinity diagram was devised by Jiro Kawakita in 1960s and is

sometimes referred to as the KJ Method.

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FLOW OF THE TRAINING DOCUMENT

Introduction to Affinity
1. Diagram

2. Steps to construct Affinity

Diagram

3. Examples of Affinity diagram

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STEPS TO CONSTRUCT AFFINITY DIAGRAM

STEPS
STEP 1: Define the issue
•Define the issue for discussion between relevant parties
- What are the difficulties / opportunities ?
- What are the critical points to overcome?

STEP 2: Brainstorming or Brain writing

•Organize the brainstorming session on the issue, collecting
free opinions from all members.

STEP 3: Put them down on Post-its

•Use one Post-it per fact or idea
•The desirable total number of Post-its is about 20. Give 3 to 4
per member in a 6-member session

STEP 4: Check the understanding of the members

STEP 5: Group ideas together by affinity

•Look for similar ideas and group them together
•The maximum number of Post-its per group is about 5.
•You can have ones that don’t belong to any group (loners).

STEP 6: Choose a title for each group

•Write the title on the Post-its above each group
•Encircle the Post-its for loners

STEP 7: Further groupings

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FLOW OF THE TRAINING DOCUMENT

Introduction to Affinity
1. Diagram

Steps to construct Affinity

2. Diagram

3. Examples of Affinity diagram

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 EXAMPLE 1: CONSTRUCTING AFFINITY DIAGRAM

EXAMPLE-1 Subject: Key points for Branding JSW Steel

Step 2:
Outcomes of Brain Brainstorming
Storming on Topic
Step 1:
Define the
Topic
Strong Steel means Promise Professionalism Customer the-
Leadershi ‘JSW’ fulfilled nucleus
p
Customer Sensitive to Customer Commitment Commitment to
Expectatio Customers problem customers
ns

Ensure Responsiven Commitmen Systematic Together we

Zero delay ess t to quality control stand
Innovation

Consistent Reduce Benchmark Right quality Higher grade

Quality variability product product
Step 3: Put
them down
on Post-its
Group the Ideas Together by
Affinity

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 Outcomes of
Brain storming
EXAMPLE-1

Group the Ideas Together by Affinity

Step 4: Check
the
understanding
of the members
Strong Leadership Ensure Zero delay Customer
Expectations
Steel means ‘JSW’ Systematic quality Sensitive to Benchmark
control Customers
Promise fulfilled Consistent Quality Customer problem
Commitment to
Innovation
Right quality Customer the-
Professionalism Reduce variability
product nucleus
Step 5:
Commitment to
Group ideas Commitment
together by
customers Higher grade
affinity Together we stand Responsiveness product

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 Step 6:
EXAMPLE-1 Choose a title
for each group

Reliable Products Customers at the Continuous

Years of Trust
& Services Core Improvement

Strong Leadership Ensure Zero delay Customer Expectations Benchmark

Steel means ‘JSW’ Sensitive to Customers

Systematic quality Commitment to
Promise fulfilled control Customer problem Innovation
Consistent Quality Customer the-nucleus Reduce variability
Professionalism
Commitment to customers
Commitment Right quality product Higher grade product

Together we stand Responsiveness

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 JSPL Brand
Years of Trust Reliable Customers at the Continuous
EXAMPLE-1 Improvement
Products & Core
Services

Completed Strong Ensure Zero delay Customer Benchmark

Affinity Leadership Expectations
diagram Steel means Sensitive to
Systematic quality Commitment to
‘JSPL’ control Customers Innovation
Promise fulfilled Consistent Customer Reduce variability
Quality problem
Professionalism Right quality Customer the- Higher grade
product nucleus product
Commitment Commitment to
customers
Together we stand Responsiveness

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EXAMPLE 2: INDIA’S PER-CAPITA STEEL CONSUMPTION

Compare with Global average (225.5 kg), India’s Per Capita Steel consumption is very
EXAMPLE-1 low (57.8 kg). Why?
Outcomes after Brainstorming Session:
High costs and limited availability
Lower productivity of labour Poor infrastructure
of coking coal
high cost of Steel
Non availability of Iron Ore Irregular supply of energy

Low grade iron ore Govt. Norms for Steel industries 72% of total population lives in rural

Means of transport in remote areas are

Poor Economical growth rate High Import costs
not developed
High costs of basic inputs &
Lack of Expenditure on R&D Non-transparent Mines allocation
services
High level taxation
Limited Domestic Steel Producers High cost of Capital

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 India’s Per Capita Steel consumption are very low (57.8 kg).
EXAMPLE-1 GDP Growth rate of the
High manufacturing Costs Govt. Norms
country

High costs and limited High level taxation

Poor infrastructure
availability of coking coal
Lack of Expenditure on high cost of Steel
Non availability of Iron Ore
R&D
Non-transparent Mines 72% of total population lives
Low grade iron ore
allocation in rural
High costs of basic inputs & Govt. Norms for Steel Means of transport in remote
services industries areas are not developed
Irregular supply of
High cost of Capital Poor Economical growth rate
energy
Govt. Norms for Steel Limited Domestic Steel
industries Producers
Lower productivity of labour

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EXAMPLE 3: MATERIAL SPILLAGE FROM TORPEDO CAR

EXAMPLE-1 Material spillage due to over turning of Torpedo car

Man related causes Method related Material related Machine related
causes causes causes

Wrong placement of ladles No proper SOP Heat sensitive material Too many cam
used in master controller switches and
Not following the complicated wiring
Untrained operator SOP
Ageing of the Cam
Many instructions to the switch Difficulty in adjusting
Tilting the ladle from
operator cam switch
remote location
Dry out of lubricants
Poor Maintenance
Master control
Reverse tilting of alignment with gear
Operator leaving the
Torpedo
control desk unattended
while tilting is going on

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EXAMPLE 4: FUNCTIONING OF QUALITY CIRCLES

EXAMPLE-1 How to make Quality circles to function systematically and Effectively?

Top Management Middle mgt. Education & Project section & Recognition
actions actions Training Progress (QCs)

Attending trg. On Undergo training on Identify Training needs Guide them to choose Recognise QCCs
TQM &QCC & QCC/TQM Teach problems first within contributions
laying down policy supervisors Invite success QCC their capabilities
and its mgt. teams from other Publicise QCCs results
Assist QCC to companies Success will enable
Understanding the Choose Problem generate confidence Bring out an exclusive
primary purpose of Adopt suitable methods
news letter for QCC
QCC-develop people Follow faithfully for teaching SQC Middle management
QCC manual Send consistently
guidance in choice of
Enable QCCs to master problem & setting goods performing circle to
Providing universal minimum basic tools
Provide enthusiasm conventions
training for all
Guidance to select &
Provide Identify potential Recognise Constance
Make a QCC manual apply the right tools
infrastructure for leaders during trg. & performance with gifts
QCC meetings reinforce & mementos
Encourage good Showing interest in the
human relation-lead Develop leadership Develop attitudinal & progress of the project at
by example within QCCs behavioral changes every stage

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EXAMPLE 5: BF FUEL RATE REDUCTION

EXAMPLE-1 Affinity Diagram for BF Fuel rate Reduction

Humidity Gas Utilization Slag Rate

Increase Raft Burden Distribution Basicity

Increase PCI Centre Coke MgO level

Check Permeability Check TGT Alumina

Check TGT Coke Moisture

Check Delta P Use bevel PCI lance

Increase O2

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END OF MODULE

If you can't describe what you are doing as a process, you don't know what you're doing

Thank You

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