islamic university of gaza - palestine chapter 5 search for solutions

Islamic University of Gaza - Palestine

Chapter 5

Search for Solutions


Types of Searches

• Unstructured search• Systematic structured search• Structured search using the

acronym SEARCH


Unstructured Search

• Encourage ideas, discourage criticism.• Avoid “groupthink.”• Use group techniques:

– Brainstorming– Nominal group technique– Groupware


Brainstorming

1. Leader: State problem clearly. 2. Group: Make suggestions orally.3. Leader: Reword and write down ideas.4. Leader: Encourage participation.5. Group: Evaluate/rank ideas.


Nominal Group Technique

1. Leader: State problem.2. Individuals: Make suggestions in turn.3. Leader: Display ideas.4. Group: Vote for best ideas.5. Leader: Tally votes.6. Group: Discuss top ideas further.


Groupware

• Allows multiple computers to communicate simultaneously.

• Permits nominal groups to be at different locations.

• Makes information widely available.• May cause information overload.


Videotape Analysis

• Operations are recorded so they can be viewed later.

• Multiple people can interact during viewing.• Operator can explain video to team

(autoconfrontation).• Results of meetings may be potential

solutions or indications for further analysis.


Systematic Structured Search

• Identify management’s perception of the problem

• See for yourself• Obtain information from the operator• Get information from the supervisor• Measure light, noise, dimension, etc.


Structured Search: SEARCH

S Simplify operationsE Eliminate unnecessary work and

materialA Alter sequence (change)R RequirementsC Combine operationsH How often


Eliminate Unnecessary Work and Material

• Eliminate unneeded work• Eliminate unneeded work• Use the exception principle• Use self-service


Simplify Operations

• Provide prepared, written information.• Use jig and fixture designs to simplify

machining.• Shift from counting to sampling.• Use forms, email, phone calls.• Generate less waste.• Automate part of a process (e.g. cleaning).


Alter Sequence

• Simplify (or eliminate) other operations• Reduce idle/delay time

– Do it now vs. do it later– “Inside machine time”– Simultaneous vs. sequential tasks– Central vs. local storage

• Reduce material handling costs– Group technology– “Bus” vs. “taxi” transportation


Requirements

• Quality (capability) costs• Initial vs. continuing costs


Quality (Capability) Costs

• Determine if the level of quality is appropriate and worth the cost.

• Review design tolerances before release to production.

• Allow for concealed costs (unreported rework causes “eddies in the river”).

• Pay attention to indirect materials, supplies, and utility costs.

• Consider selective assembly.


Initial vs. Continuing Costs

• Minimize life-cycle costs, not just initial purchase cost.

• Identify maintenance, operating, and utility costs.

• Expect noneconomic behavior when cost is ignored.


Cost vs. Quality Curve


Combine Operations

• Both general purpose and special purpose materials should be considered.

• Specialist job descriptions may be inefficient.• Central departments allow economies of scale.• Advances in communications can be used to

centralize.• Supervisors may resist consolidation.


How Often?

• Use economic lot size calculations.– Trade off setup costs vs. inventory for “make”

items– Trade off purchasing cost vs. inventory for

“buy” items• Analyze maintenance, service, and

inspection activities.• Use red/yellow/green labels to concentrate

resources where needed.

islamic university of gaza - palestine chapter 5 search for solutions

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