Problem Solving Techniques - LEAN
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Transcript of Problem Solving Techniques - LEAN
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Problem Solving
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Problem’s are the Golden Eggs
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We can’t solve problems by using the same thinking we used when we
created them….
“In any moment of decision the best thing you can do is the right thing, the next best
thing is the wrong thing, and the worst thing you can do is nothing”
Do not put a Band Aid – Solve the root of the problem
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Barriers to Problem Solving
• Failure to recognize the problem – no sure what the problem is
• Conceiving the problem too narrowly, not sure what is happening
• Making a hasty choice, not sure what you want
• Failure to consider the feasibility of the solution
• Failure to consider all consequences, not enough resources
• Failure to know to communicate what is possible
• Failure to define what YOU did that was responsible for your success
• Team attitudes like complacency, ridiculing others ideas, lack of accountability, dysfunctions, fear of change, lack of trust and doubts
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Attitudes That Kill Creative Ideas
Don’t be ridiculous
That beyond our responsibility
It’s too radical a change
Top management will never go for it
It costs too much
That’s not our problem
Are our competitors doing it
It isn’t in the budget
We don’t have time
We’ve never done it before
That’s not our problem
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Assumptions Vs Observations
Don’t Jump over the Problem
Be with theProblem
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Don’t Jump over the Problem
• Jumping to a solution orients the team to deploy only one thing, which could be insufficient or just wrong.
• It stops the team’s search to find the true reason for the problem.
• It reduces your effort to find a real solution.
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Be with the Problem• Explore the current
work situation
• Go to the place of work where problems happen, to gain Insights into the work where work is Done
• You learn, what is really happening…
• It avoid False Starts!!!
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Problem….
Problem is the discrepancy between the current situation and the standard for that situation
A standard is a specific established “KNOWN” expectation of what should be for a given situation
The current situation is the way things are now
A discrepancy is a measurable or quantifiable difference between a standard and the current situation
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FOUR-PHASE PROBLEM
SOLVING PROCESS
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About PDCA Authors
Walter ShewhartDiscussed the concept of the continuous improvement cycle (Plan Do Check Act) in his 1939 book, "Statistical Method From the Viewpoint of Quality Control
W. Edwards Deming Modified and popularized the Shewart cycle (PDCA) to what is now referred to as the Deming Cycle (Plan, Do, Study, Act).
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When do we use the PDCA
• 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
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Problem solving Guide
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Problem solving Guide
Clarify the problem
Break down the problem
Target the setting
Determine root causes
Develop countermeasures
See countermeasures through
Confirm results & process
Standardize process
PDCA
PDCA
PDCA
PDCA
PDCA
PDCA
PDCA
PDCA
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Step 1: Clarify the Problem
• We need to understand the current situation (Measured), Ideal situation (Standard).
• Why is it a problem? What is the KPI affected? What is the cost? Relation to objective? Why is it a priority?
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Step 1: Clarify the ProblemWhat is a problem?
• Anything that deviates from the standard or target
• A gag between actual and desired condition
• An unfulfilled customer’s need
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Step 1: Clarify the Problem
Problem type - 1 Problem type - 2 Problem type - 3
Standard not AchievedStandard achieved, but a higher standard is now
required
The new higher standard is target
Actual (100% on time @ 2 weeks lead time
Performance to standard varies (not
consistently achieved
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Step 1:Evaluate The Problem
The criteria you use to guide this evaluation include: Importance - How serious is the problem in light of cost, safety,
or quality, etc?
Urgency - How soon should it be solved to avoid more serious problems.
Tendency - Is the problem getting worse, staying the same, or getting better?
Problems Important Urgency Tendency
1.
2.
3.
4.
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Step 2 : Break down the problem
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Step 2 : Break down the problem
• Requires to study 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
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Step 2 : Break down the problem
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Step 2 : Break down the problem
• Specify the point of cause by studying the process
• Specify the point of cause is necessary for effective Root cause Analysis
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Step 3 : Target Setting
Target
Characteristics:
Must be quantifiable
Measurable
Achievable
Time Bound
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Step 3 : Target Setting
Do what: Increase
To what: Percent of usable parts produced on presses
4, 5 and 6
How much: From 90% to 95%
By when: June 1, 2008
0
10
20
30
40
50
60
70
80
1-May 8-May 15-May 22-May 29-May 1-Jun 5-Jun
Avg. percent of weekly
usable parts on presses
4,5,& 6
5%
std 95%
Std
Avg. percent of weekly
usable parts on presses
4,5,& 6
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Step 4: Determine the Root Cause
Why Root Cause Analysis?
• To solve problems on structural basis
• To ensure problems do not return
• To ensure sustainable improvements are made.
• Identifying potential causes
• Challenging those potential causes
• Making reasonable assumptions about the most likely cause of the problem
• Investigating to get the needed facts while continually asking “Why?”
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Step 4: Determine the Root Cause
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Step 4: Determine the Root Cause
• Cause and Effect Diagram
• 5 Why’s
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Cause and Effect Diagram
• it ask yourself, "What Happened?" and "Why?“
• "What happened?" tells you the Effect."Why?" tells you the Cause.
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Cause and Effect Diagram
• Try to make your “Effect” measurable – can you graph it?
• Sometimes, the ‘5M’s’ are replaced with ‘P’s’ for Office processes:
• Do not waste time discussing the branches
Just Do it !!!!• You can use what fits your needs
PoliciesPeopleProceduresPlant (Facility)Programs (Software)
PricePromotionProcessesPlanet
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5 Why’s
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5 Why’s
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5 why’s
• Don’t need to do exactly 5 Why’s ?
You may find yourself using 3 to 7 “Why’s” or more on a problem
“Strive for 5” Why’s (don’t quit too early!)
Use as many as you NEED to get to ACTIONABLE Root Cause
Base “Why’s” on Facts and Observations, not Opinions
• Test your “Why” logic by using “Therefore” in reverse.
Make the tools work for you, don’t be a slave to the tools
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Step 5 : Develop Countermeasures
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Step 5 : Develop Countermeasures
Evaluation of ideas
1. Cost-benefit Analysis: The method is usually run in three steps:
Definition of all elements causing costs of idea implementation
Definition of all elements causing benefits of idea implementation
Comparison sum of all costs with the sum of all benefits
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Step 5 : Develop Countermeasures
2. Evaluation matrix
The main goal of evaluation matrix is to evaluate an
idea in accordance to several factors or criteria.
Score = Rating x Weight
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Step 5 : Develop Countermeasures
• Good problem solving and countermeasure preparation will drive an organization to:
Productive self-criticism
More robust systems and processes
A higher-level understanding
The countermeasure cycle is a team effort!
Effective Problem Solving with robust countermeasures leadto better processes!
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Step 6 : See Countermeasures through
• Share information with others by informing, reporting and consulting
• Review the progress of the action plan and the results in regular review meeting
• Ensure that your countermeasures do not create adverse effect to other upstream or downstream processes.
• If there’s a gap between implementation and people engaging with the new process, you must retrain.
Do Not Merely Communicate By Email
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Step 7 : Confirm Results & Processes
Evaluate if target was achieved or not
Evaluate the process and ensure that it is sustainable
Confirm negative and positive effects
Share evaluation with people involved
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Step 8 : Standardize process
• Set successful processes as new standard
• Share the new standard.
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