Problem solving techniques pdf

Problem solving techniques pdf

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  7/21/2015 1 By: Rajesh Sahasrabuddhe WHAT IS“PROBLEM ” ? “PROBLEM” means……. • Your part is not as per specification ? • Your process is not in your control? • Your internal rejection % is very high? • Your delivery performance is less than 100 %? • Your external rejection % is very high? • Your waste % is very high? etc………. You want to solve problem….. • Temporarily….. or • Permanently…… • And become problem solver Have got Problem ? Do what you can, where you are and with what you have got.
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  7/21/2015 2 Knowledge So what todo…..? There are ways and techniques for solving each and every problem but the urge for solving, make these techniques powerful. Because……….. Even to the hardest problems... Just Urge to solve it… So how to do it……? Solve the problems such that…
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  7/21/2015 3 So let usknow types of problem solving techniques……… ? ? ? ? 1 2 3 4 ….. 1. Definethe problem 2. Build a Team 3. Containment action 4. Determinethe root cause 5. Verify the root cause 6. CorrectiveAction 7. Preventive 8. Congratulatethe Team And Many others…… P Why use this approach…..? • This technique has proven its usefulness in other companies • Common methodology – everybody understands how • Focus on Fixing it - first time right • Define priorities • Sharing the lessons learned with others When do we use this technique……….? • Significant or repetitive complaints • Repetitive human errors occurring during a specific process • Repetitive equipment failures associated with a specific process • Performance is generally below desired standard • ... Major impact or Repetitive issues This technique is based on……….
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  7/21/2015 4 How does thetechnique in more detail look like……….? 1… Clarify the problem 2… Break down the problem 3… Target Setting 4… Determine Root Cause 5… Develop Countermeasures 6… See Countermeasures through 7… Confirm Results & Process 8… Standardize process - Sustain the gain How to fit PDCA with this technique…? Problem Solving Guide… Let us take Step : 1- Clarify the Problem • What do you understand by the problem ? • What is exactly the problem is ? • How you define the problem ? • Is problem the gap between desired and actual ? • What is and how is affected by the problem – How you say it is a problem ? Problem Solving Guide… Step :1 Clarify the Problem Desired / Ideal Situation Actual / Current Situation Gap = ProblemGap = Problem • What we understood is problem means “GAP” between desired and actual situation. • Now also identify who is getting affected by Problem, what is the cost, what is priority etc…. Step :1 Clarify the Problem
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  7/21/2015 5 Step :1 Clarifythe Problem Let us take type of problems in easy way Type 1 : Standard not achieved The Standard = 100 % on time delivery Actual = 82 % on time delivery 15.50 mm Requirement is 15.75 ± 0.1mm ( 15.65 to 15.85 mm) Step :1 Clarify the Problem Type 2 : Standard is achieved but a higher standard is required now Actual 100 % on time delivery @ 2 week lead time New standard 100 % on time delivery @ 1 week lead time Now new higher standard is target…. Step :1 Clarify the Problem Type 3 : Consistency in the achieving result is not there Time The standard Actual Step :1 Clarify the Problem Step 2: Break down the problem Step 2: Break down the problem Problem ( Complex ) Problem Problem ProblemProblem Problem Problem Problem ProblemProblem Break Down Break Down Break Down Ask questions like why, where, when ,who etc… Prioritized problem Point of Cause
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  7/21/2015 6 • Requires tostudy the process to detail • Dedicate sufficient time for the breakdown • Study the steps of the process, interact with people, get data, documents, understand tools: Learn • All problems can be divided into smaller defined problems: by region, location, department, product, channel, customers, etc. • Specify the point of cause: the problem is present in a specific part of the process Step 2: Break down the problem Step 2: Break down the problem Step 3: Target setting Step 3: Target setting What are GOOD and BAD targets …….? • When you set the target you should be very specific about the requirement or desired result of the actions you are going to take. • What • When • Where • How much Step 3: Target setting Step 4: Determine root cause
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  7/21/2015 7 Step 4: Determineroot cause Followings are the ways of finding root cause……. • A team is require to do this activity • Please note that any thing come in mind as a cause you should write • DO not criticize anybody for silly thought • Do not get trapped by your own train of thinking • Note down all the thoughts came from team’s mind Step 4: Determine root cause Brainstorming Step 4: Determine root cause Pareto’s principle says you should attack first on the cause which are affecting 80% Pareto Analysis Step 4: Determine root cause Fishbone Diagram Step 4: Determine root cause Fishbone Diagram Problem : We start fishbone diagram with problem statement Man Method Material Machine Measurement Environment Then we will add Headers Then more causes added as smaller branches Mark problem if proved • Try to make your effect measurable – Can you plot graph for the effect ? – Can you calculate the figures for effect ? • Sometimes ‘6M’s’ can be replaced with required headers like : – Policies – People – Procedures – Plant (Facility) – Programs (Software) Step 4: Determine root cause
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  7/21/2015 8 5W1H Step 4: Determineroot cause Example 01 Step 4: Determine root cause Example 02 Step 4: Determine root cause 5W1H Step 4: Determine root cause Step 4: Determine root cause Check sheet • Visualization of measurements • Upper & lower specification limits + mean • Location of measurements helps analysis Step 4: Determine root cause Control charts
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  7/21/2015 9 Step 5: Developcountermeasure Step 5: Develop countermeasure Step 5: Develop countermeasure Psychology of Countermeasures Step 6: See Countermeasure Through Step 7 : Confirm Results & Processes
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  7/21/2015 10 Step 8 :Standardize process Step 8 : Standardize process Kaun Banega Carodpati Question No. 1 Answer  None of the above, All are valid Question No. 2  After identification of actionable root cause Answer  After identification of actionable root cause  All of the above are steps in the Problem-Solving process Answer Question No. 3
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  7/21/2015 11 Question No. 4 AnyQuestion THANK YOU for your patience