A3 problem solving

1. A3 Problem Solving
Prashant Uttarkar
A3 problem solving is a structured problem-solving
and continuous-improvement approach, first
employed at Toyota and typically used by lean
manufacturing practitioners. A3 refers to a European
paper size that is roughly equivalent to an American
11-inch by 17-inch tabloid-sized paper. A3 process is
a way to look with "new eyes" at a specific problem
identified by direct observation or experience.
The purpose of the A3 Report is to:
 Document the learning, decisions, and
planning involved with solving a problem.
 Facilitate communication with people in other
departments.
 Provide structure to problem-solving so as to
maximize learning.
The idea of this approach was created by Toyota as
part of Toyota Production System (TPS) to describe
the process of getting report-writing down to one page.
For Toyota, this was just a format for structuring a
report so that it could be clearly and consistently
communicated on one page of paper, reducing the
waste of report writing and report reading. There are
three A3 styles--- Proposals, Status Reports, Problem
Solving. We have focused on the problem-solving
report simply because it is the most basic style, making
it the best starting point.
Steps are used to implement A3 problem solving:
1. Issue – a clear, focused, stand-alone statement that
defines the problem.
2. Background – details that cannot be described in
the Current Condition drawing and useful baseline
metrics.
3. Current condition – a drawing that conveys a
complete understanding of the current situation is
essential in order to realize what improvements
may be necessary.
4. Goal – a quantitative statement that will form the
basis for how improvement will be measured.
5. Root cause analysis – carrying out the Five Whys
analysis or the Ishikawa (fishbone) diagram.
6. Target condition – a drawing that conveys a
complete understanding of what the situation will
look like once the improvements have taken hold
is placed on this step.
7. Countermeasures – a listing of the improvements
needed to attain the Target Condition.
8. Implementation and cost analysis – a listing of
specific tasks that will lead to improvements,
along with timelines, ownership and the expected
outcomes.
9. Test – a small pilot conducted over 1–2 weeks.
10. Follow-up/audit – a description of an audit plan,
the results of the audit plan, and, if needed,
recommendations for how the next A3 Reports
will become standard work.
The BENEFITS of using A3 thinking are:
1. Quicker problem solving, easier planning,
Team development.
2. Creates a consistent approach to solving
problems throughout the entire organization
3. Requires a balanced way of thinking both
visually and analytically (Right Brain/Left
Brain).
4. Reduces complexity and keeps focus on the
problem.
5. Thinking process, facilitates communication,
and builds consensus.
6. Provides a visual representation of data that is
easy for everyone to understand.
Conclusion:
A3 thinking is a management approach that turns day-
to-day management into a learning practice for the
whole organization. The A3 approach is also known as
SPS, which stands for Systematic Problem Solving.
Tools Supporting A3 Analysis-- Fishbone Diagram,
Five Why Analysis, PDCA Action Plan.
Reference:
1. K. Kanyinda, I. J. Lazarus and O. A. Olanrewaju “A3 Problem Solving: A
Case of Assembly Line Downtime” Proceedings of the 2nd African
International Conference on Industrial Engineering and Operations
Management Harare, Zimbabwe, December 7-10, 2020.
2. Radim Lenort, David Staš, David Holman, Pavel Wicher “A3 method as a
powerful tool for searching and implementing green innovations in an
industrial company transport” TRANSCOM 2017: International scientific
conference on sustainable, modern and safe transport.
3. Quick Guide to A3 Problem Solving.
4. Larry Rubrich “A3 Problem Solving: What It Is ... and What It Isn't “
5. Greg Jacobson “How A3 Software Supports Problem Solving” Oct 16, 2017.
6. José R. Ferro “The Hidden Benefit to A3 Thinking”
May 12, 2015. The Lean Enterprise Institute Inc.
7. “Lean Six Sigma A3 Process Keeps Problem Solving Organized December”
18th, 2017, SixSigma.us.
8. www.google.com