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Problem Solving MFG
The problem-solving app begins by gathering pertinent information regarding the nature of the issue, its exact location, the participants involved, and the actual and target outcomes. A clear problem statement is formulated, describing the identified loss, and specifying when and where it occurs. The issue is then categorized as either chronic or sporadic, based on an assessment of observed results over time. Problems that frequently halt operations are deemed chronic and require a more comprehensive approach for resolution. In contrast, those with lower frequency interruptions are classified as sporadic and typically utilize fewer tools for resolution.
Before determining whether an issue is chronic or sporadic, a base condition assessment of the equipment or process is conducted. Any discrepancies in performance compared to this baseline are addressed before moving forward. The base condition standards include checks for equipment or machine component tightness, cleaning conditions against specifications, and proper lubrication in accordance with guidelines. After verifying the base condition, the end user is prompted to update the problem statement if needed. The app further checks whether the issue persists by asking the user to confirm, allowing for a comparison of actual results with those recorded initially.
Subsequently, the app guides the user through a structured execution of problem-solving activities accompanied by one-point lessons. These lessons serve to educate the user on the theory and expectations of each step, acting as a coach and subject-matter expert, building the user's confidence in the data collection process. Each process step is designed to collect specific data that directs the user to the next task, ultimately leading to the identification of the likely root cause(s) of the issue. Each root cause is then examined to establish new or improved standards aimed at ensuring a permanent solution. These standards are agreed upon by others within the organization, becoming the new execution standards that will help prevent the problem from recurring.
The training and process instructions encourage the user to engage with others, including subject matter experts regarding equipment and processes. A variety of sophisticated problem-solving tools are made accessible to all manufacturing personnel without needing direct coaching from a lean manufacturing expert. The app steers the process based on results and utilizes simplified training tools to assist individuals or teams in addressing chronic manufacturing problems.
For Sporadic problems, the app employs a 5 Why root cause analysis, along with steps for standard setting to prevent recurrence. The chronic problem statement is further refined through a meticulous analysis using the 6W2H approach. Once polished, the statement reflects the effects of various causes identified in the Ishikawa (Fishbone) analysis. Potential causes are ranked through a series of scoring activities to pinpoint the most likely contributors. Each of these top causes undergoes a critical examination using the 5 Why method. Standards are then established to address those root causes and prevent their recurrence.
Users are prompted to recognize the contributions of involved colleagues, and progress is encapsulated in an A3 report, illustrating the tools utilized, the new standards set, and a plan for implementing these standards. The resolved problem is digitally documented as part of the user’s problem-solving journey. This journey folder will store the A3 summary report for future benchmarking and reapplication of content and standards across similar industries, process types, and technologies. Most importantly, this record serves as a testament to the employee's contributions to the overall success of the business or company.
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