problem solvimg techniques

7/31/2019 Problem Solvimg Techniques

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Problem Solving Techniques

Training

OHTs


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Objectives

1. Provide a structured framework for problem solving

2. Ensure problems are properly defined, based on facts

3. Provide techniques for root cause analysis

(both simple and complex problems)

4. Demonstrate how to evaluate possible solutions

5. Ensure solutions are sustainable6. Integrate structured problem solving with other

improvement processes in your company


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Prerequisites

To be successful you must provide:

Time for analysis before jumping to conclusions

Patience & discipline to follow the Six Steps Involvementof the right people

Management support & encouragement

Customisation & simplification

Standardisation a way of life

Exercise on p.5


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The PDCA Cycle

Plan

Do

Check

Act


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Problem Solving Steps


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Step 1: Recognise

the Problem


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What is a problem?

SOMETHING THAT IS NOT NORMAL


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Identifying Problems

We need 3 things:

Knowledge to distinguish between normal & abnormal

Mechanisms to expose abnormalities ASAP

Willingness of people to report problems without fear


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Step 2: Define

the Problem


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Defining the Problem

Alice : Which way do I go from here?

Caterpillar : That depends on where you want to go.

Alice : I dont know where Im going.

Caterpillar : Then it doesnt matter which way you go.

Lewis Carrol

Alice in Wonderland


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Problem Definition:

5W1H

WHAT is the problem or symptom?

WHERE did it happen?

WHO was involved? (Skill-related?)

WHEN did it happen?

WHICH trends or patterns are visible?

HOW big is the problem?


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Problem Definition:

5W1H

WHAT? Skew labels (both front and back labels)

WHERE? On line 6

WHO? The new setter (John) and the operator (Mary)

WHEN? Night shift, after change-over to the new size

WHICHTREND?

The labels were skew from the start of the run.

It has not happened before.

HOW BIG? QA had to reject two pallets of product.


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Pareto Diagram

Bottles

fallov

er

Linebuild

-up

Sticky

rubber

s

Waitin

gontemp

Glassbre

akage

Exitst

arwheel

Waitin

gonproduct

Lowvac

uum

Infeedscrolltiming

Temperaturedr

Filler/de-

Problem

0

5

10

15

20

No. of stoppag


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Step 3: Collect and Analyse

Data


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In God we trust for everything else

we rely on data.

Motto of Six Sigma Black Belts


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Recording Data

Production log

Output

Material used

Stoppages

Reject

Tally sheets


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Problem Solving Steps


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Step 4: Determine

the Root Cause


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The Eleventh Commandment

Thou shalt not jump to premature conclusions

Have a good facilitator

Use groups

Examine the facts

Ask many questions

Use data

Follow a structured process


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Creative & Analytical Thinking

Define the problem (5W1H)

Select the best solution

(Evaluation, cost-benefit)

Creative :

Analytical :

Creative :

Analytical :

Analytical :

Define possible solutions(Brainstorm with Fishbone)

Find all possible causes(Brainstorm withFishbone)

Find real root cause

(verification, 5 Whyand PM Analysis


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Brainstorming

The best way to get a good idea is to get lots of ideas


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The Rules of Brainstorming

1. No criticism - either verbal or non-verbal

2. Record all ideas exactly as they were stated and visible toeveryone (e.g. on a flipchart)

3. Freewheel - encourage crazy ideas

4. Generate as many ideas as possible

5. Allow people to think

6. Give the quiet people a chance too

7. Allow ideas to incubate (for a few days) before evaluating

8. Have FUN!


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The Brainstorming Session

Step 1: Write down and emphasise the rules of

brainstorming.

Step 2: Clearly define the issues to be brainstormed.

Step 3: Allow everyone time to think individually.Step 4: Let the ideas flow and write them down.

Step 5: Stop when the ideas dry up.

Step 6: Allow the ideas to incubate.

(Step 7: Evaluate the ideas, using experts orinformation where required.)


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Fishbone Diagram

MACHINE METHOD

MATERIAL MAN / WOMAN

PROBLEM:


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METHODS

MAN

MACHINE

MATERIAL

PROBLEM

FallingBot t les

causingst oppage

Bot t les pileupagainst siderail

Defect s inconveyor belt

Conveyor st opsand st art s

Incorrect conveyorspeed

Conveyor beltnot inspected

Defect ivebot t les

Siderails rough

Bot t les unst ableduet o short

conveyor

Dirt st ickingt obot t les

Glass on conveyorbelt

Poor maint enanceofvariablespeed drive

Verification


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5 Why

1. Define the problem

2. Ask Why? to identify the cause

3. Keep asking Why? until you

come to a deadend the root cause

Root Cause

Why?

Why?


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5 Why

Why?

Problem: Switch tripped

Bearing seized

Why? Lack of lubrication

Why? Lubrication pump not effective

Why? Foreign particles in oil

Why? Oil filter defective

Why? Not replaced regularly

Why? No preventive maintenance


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5 Why


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Step 5: Select a Solution


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Is there a best solution?

BenefitsCosts &risks


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Solutions Fishbone

(Brainstorming)

MAN/WOMAN

MACHINEMETHODS

MATERIAL

PROBLEMBottles

Falling Over

Lengthen infeedconveyor toallow bottlesto stabilise

Check conveyor

belt for defects

Repair variablespeed drive

Train operator

to do regularLook-Listen-Feel

inspections

Train operatorin SOP

Check bottles

againstspecification andtake up withsupplier if defective


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Evaluate the Solution

1. Identify all criteria the solution must adhere to.

2. Give each a weighting out of 5 to indicate importance.

3. List potential solutions

4. Assess each solution with regard to adherence to thecriteria and give a score out of 5.

5. Add up answers for each possible solution and write the

total.

6. The solution with the highest score is the most feasible.


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Step 6: Implement and

Control


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Implement and Control

Track the solution:

action plan

solutions tracking chart

Make it stick: SOPs

Failsafe devices

Bottle the solution: one-point lessons

troubleshooting diagrams

improvement records

Plan

Do

Check

Act


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Action PlanDate Action Who When

21/9 Check SOP for correct conveyor

speed

John 22/9

21/9 Compile Look-Listen-Feel inspection

list

Linda 28/9

21/9 Fix variable speed drive Willie 30/9

21/9 Train operator in SOP and LLF

inspection

Linda 15/10

21/9 Check bottles against spec. Kevin 30/9

21/9 Inspect and fix conveyor belt Sipho 22/9

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