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IE 3 - Activity #2

This document provides guidance for a problem identification and analysis assignment in an Introduction to Industrial Engineering course. The assignment involves: 1. Answering short questions about identifying a problem, conducting a why-why analysis to find causes, and giving examples of efficient processes. 2. Completing a paper that determines a problem at an establishment, identifies possible root causes using tools like brainstorming or an Ishikawa diagram, describes the main process using a flowchart, assesses methods for inefficiencies and ways to reduce waste, and is graded on completion of these tasks. 3. An 8 wastes cheatsheet is provided to help identify types of waste like defects, overproduction, waiting,

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Jamielynne Ugay
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22 views4 pages

IE 3 - Activity #2

This document provides guidance for a problem identification and analysis assignment in an Introduction to Industrial Engineering course. The assignment involves: 1. Answering short questions about identifying a problem, conducting a why-why analysis to find causes, and giving examples of efficient processes. 2. Completing a paper that determines a problem at an establishment, identifies possible root causes using tools like brainstorming or an Ishikawa diagram, describes the main process using a flowchart, assesses methods for inefficiencies and ways to reduce waste, and is graded on completion of these tasks. 3. An 8 wastes cheatsheet is provided to help identify types of waste like defects, overproduction, waiting,

Uploaded by

Jamielynne Ugay
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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University of the Philippines Diliman

Department of Industrial Engineering and Operations Research


IE 3: Introduction to Industrial Engineering

Documentation and Problem Identification Tools,


Methods Study
Maximum possible score: 45 / 45

Part I. Short Answers (20 pts). Answer the following questions by group. No need to answer
the other questions shown on the lecture video.
1. Think of ANY problem. Write a PROPER problem statement for it.
2. Using the same problem in #1, perform a Why-Why Analysis to identify causes of
that problem. Think of at least two simple solutions that may help solve the
problem.
3. Give an example of a productive system/process/machine not discussed in class.
Explain how it is efficient and effective.
4. What do you think is the most painful type of waste? Give an example of it not
discussed in class.

Part II. Paper (25 pts). Read the following and accomplish the outputs for each task.
Include your outputs from the previous activity, incorporating the revisions needed. If you
changed your establishment/organization, also include the outputs for the previous tasks.
However, re-doing the previous tasks will not merit points anymore. Use the paper
template provided and properly cite your sources, if any.

1. The Problem

What you will do Guide Output Points

Determine the problem or What is the problem or what can be 1 sentence 5


room for improvement of improved in the performance of the problem
the establishment establishment? statement

Assign possible root You may use Brainstorming, Ishikawa Possible root 5
causes of the problem Diagram, Why-Why Analysis. List causes of the
down as many as possible. If you will problem.
use Ishikawa Diagram, Other versions
of Ishikawa Diagram have 9 fishbones
(Man, Material, Machine, Methods,
Management, Mother Nature, Money,
Measurements, Maintenance).

1
University of the Philippines Diliman
Department of Industrial Engineering and Operations Research
IE 3: Introduction to Industrial Engineering

2. The Process

What you will do Guide Output Points

Describe the How is the process Description of the main 5


establishment’s main done step-by-step and process. Good if presented
process who does it per step? using a flowchart.

Assess the efficiency of What inefficiencies are List of inefficiencies/waste in 5


methods. there in their methods? the methods. Classify
Be guided by according to what type of
DOWNTIME and Value waste. This can be in bullet
Stream Mapping. form. You may include a
Value Stream Map (or
combine this in the process
flowchart).

Provide ways to reduce How can the wastes Possible solutions to improve 5
wastes. present be reduced? their methods.
Be guided by
DOWNTIME, the 8
Wastes Cheatsheet,
and the Guide to
Problem Solving on the
succeeding pages.

2
University of the Philippines Diliman
Department of Industrial Engineering and Operations Research
IE 3: Introduction to Industrial Engineering

8 Wastes Cheatsheet
Waste Definition Examples Solution

Defect Does not meet Defective products. Service Rework. Sell. Study root
customer’s error. Scrap. Mistakes. cause of defects. Prevent
requirements. Corrections. causes. Instructions.
Quality control. Error-proof.

Overproduction Making Too much stock due to Discount. Reuse. Lessen


something that producing at full capacity. production. Devote time
nobody is going Hoarding. instead to other jobs.
to buy.

Waiting Idle. Work has Queueing time. Waiting for Workflow balancing.
stopped. people/provider. Machine Improve process. Do other
downtime/failure. Bottleneck. things.
Reloading of machines.

Not Utilizing Unused Clerical work. Mechanical work. Encourage employee


Talent employee Deskilling. Right person on the creativity and feedback.
creativity due to wrong job. Not listening to Robotize mechanical work.
menial jobs. employees. Form teams.

Transportation Movement of Delivery. Logistics. Movement Proper layout. Proper


product from from storage or from office to setup. Relocation.
one station to office. Wasted effort due to Technology.
another that distance.
takes time.

Inventory Piling up of Work in process. Backlog Appear only exactly when it


things to orders. Inventory breakage or is required. Inventory
process. Any obsolescence. management. Have only
supply in enough.
excess.

Motion Unnecessary Worker movement that is Simplification of job. Time


movement of unnecessary. Finding items. and motion study.
people. Overexertion. Reaching. Ergonomics. 5S. Good
setup of workplace.

Excess Processing that Inspection. Extra processing Value Stream Mapping.


Processing does not add that can be avoided or customer Prevent reasons for quality
value to the does not want. check. Improve process.
product.

3
University of the Philippines Diliman
Department of Industrial Engineering and Operations Research
IE 3: Introduction to Industrial Engineering

Guide to Problem Solving

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