1st Edition

Solving Complex Industrial Problems without Statistics

ISBN 9781498759083
Published May 24, 2016 by CRC Press
143 Pages 6 Color & 70 B/W Illustrations

USD $105.00

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Book Description

Presenting: Problem Solving Sans Statistics

Enhance your problem-solving skills, and improve your company’s profitability using the methods outlined in Solving Complex Industrial Problems without Statistics. Introducing a process that involves working through problems and solutions without relying on complicated statistical design or analysis, this book pulls away from data-driven thinking and provides the problem solver with a new way of solving problems.

Utilizing techniques that have been applied in facilities throughout the U.S., Canada, Italy, China, and Hong Kong, it demonstrates the use of process and problem differences and similarities, and provides a better understanding of analogous comparisons. The book incorporates visual analysis tools and problem examples in a format that facilitates comprehension and learning, presents novel concepts that do not require numbers or statistics, and provides a better understanding of the solution system/process overall.

Each chapter presents new information, as well as case studies that include:

  • Different problem situations
  • Short histories detailing the operation, condition, and circumstances that were present at the time of each study
  • Photographs, sketches, or tables with simple explanations to describe the circumstances, conditions, and the actions taken
  • Methods of solution in rudimentary form
  • Chapter summaries to review important mechanisms and workings
  • Final summaries to tie together the important methods and techniques that facilitate easy problem solutions

Solving Complex Industrial Problems without Statistics provides valuable insight into the solution of complex quality and manufacturing problems, without the use of statistics, and is essential to anyone involved in quality, control, problem-solving activities, or total quality management.

Table of Contents

A Different Approach
Visual Observation
Concept Sketches
Clue Uniqueness
Comparison of Twin Sets
Group Twin Set Comparison
Data Ranking
Fractional Analysis
Simple Analysis

Assembly Problem
Flywheel Bolt Assembly

Faulty Thinking
Individual Differences
Individual Action Has Consequences
Combustible Components
Data Collection
Clues to the Cause

Batch Mixing Problem
Process Problems
Steps in the Process
Problem Occurrence
Investigation Findings

Component Assembly
Operator Skill and Knowledge
Plan of Attack
Establishing a Visual Guide

Assigning Responsibility
Creating Identification
Problem Description
Specific Problem
Proposed Solution

Electrical Components
View of the Problem
View of the Defect
Plan of Attack
Review of Job Instructions
Problem Control

New Process Development
New Process Initiation
Rationale for Improvement
Lack of Operating Instructions
Process Conception
Initial Runout
Lack of System Knowledge
Developing an Operation Plan
Unswerving Work Application

Innovative Solutions
Surface Contact Temperature
Reductions in Force
Battery Charging Area
Moving Assembly Problem

Electronic Chip Wafer
Following the Job Routing

Machining Problem
Machining Evaluation
Create a Ranking System
Create a Sketch
Present Result Data
Recap of Machining
Another Example

Systemic Chaos
Truck Head Processing
Background Information
Dissimilar Testing Devices
Problem Cause

Sequester and Shutdown
Notification of Sequester
Measurement System
Measurement Rationale
Component Measurement
Data Evaluation

Corroboration of Results
Simple Charts
Judge Five Before Against Five After
Comparison of Twin Sets

Appendix: Glossary of Terms

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Ralph R. Pawlak is a graduate of Erie Community College, General Motors Institute, and The State University of New York, Buffalo. He earned an associate of applied science in industrial technology, a bachelor of science in industrial engineering, and a master of education, respectively, from these institutions. During his extensive career with General Motors, he served in several positions at various facilities in Tonawanda, New York; Danville, Illinois; and Romulus, Michigan. He also engineered start-up operations for Fisher-Price in China and Italy. Toward the end of his career, he returned to General Motors as a contract employee who was used as a consultant to suppliers.


"This concise book contains a wealth of practical information a manufacturing engineer will find useful in solving every-day quality problems. The ample supply of case studies covering a wide range of topics is particularly appealing. The book is clearly written, logically organized and well presented. The author has excellent credentials as a practitioner."
—Duc Pham, University of Birmingham, UK