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Problem Solving Tools –
In-depth Analysis
www.optimumfx.com
In-Depth analysis tools
When you have either a significant one-off defect or
problem, or a series of minor problems over a prolonged
period of time that requires a detailed approach
Benefit of formal problem solving
• Think of a typical re-occurring problem that’s worth 60min/week
– Fallen bottles on a labeller infeed
– Collation errors in a packer
– Materials issues in a palletiser
– Startup issues following on a Monday morning
• Imagine how many hours have been spent observing this issue. How many engineering fixes
were attempted. How much money in parts has been spent over the last 6 months that this has
hurt you
• Now imagine getting a team to sit in an office to work through a structured process for 2-3hr in
one go and imagine the most frequent complaint:
“This is all very good, but it’s just too slow...we don’t have time for this”
• How many hours of resource have you wasted by NOT doing this sooner?
• When you have something that’s cost you 60min week for 3 years is 3 hours in one week
really too slow?
Introduction to a formal problem solving process
• As an example of an off-line problem solving process we will demonstrate Kepner-
Tregoe’s Problem Analysis process
• This is ideal for significant issues or repeat offenders and may involve a team of
people for a reasonable period time
• Getting a great result = follow the process
• Ensure that the team has a trained facilitator who will ensure that the process is
followed and that the team are not jumping to unfounded conclusions
• Potential issues
– A good RCA is a process. A process is only effective when it is followed robustly
– Can require strong leadership skills from a facilitator to ensure that the team stays on target
Identify possible causes from experience:
- Faulty sim card
- Phone damaged
- Disconnected
- Phone not allowed to travel
- Flight mode switched on
Problem:
- I can’t make phone calls
Evaluate possible causes:
- If_____is the true cause of _____how does it
explain the Is and Is Not information?
- What assumptions have to be made?
- Which cause best explains the Is and Is Not
information?
CAN SOMEONE HELP
ME?
IS IS NOT
What
Object has the
deviation
Where
Is object when
deviation occurs
When
Was deviation
observed first
Extent
How many
deviations on obj
- My phone - Colleague’s phone
- Where I am standing now
- The hotel, the airport, conference room
- Calling features and data features
- At the airport in England
- Any other feature on my phone
- Since I got off the plane
- Continuously
- On this trip
- Before getting on the plane
- All time since getting off the plane
- On other trips abroad
- 1; my phone
- N/a
- One; my ability to make calls+data
- No trend
- All the other phones
- N/A
- All other applications not working
- No trend
Define:
- My phone can not make calls
Problem Analysis Example
Generic Problem Analysis
Bringing it together…
5 Whys
Defined problem
Refined problem
IS/ IS NOT
Probably cause
Accountability and what
happened/when
History
What’s changed
Possible causes
Action tracker for each stage of
the problem solving process

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In-depth problem solving tool

  • 1. Problem Solving Tools – In-depth Analysis www.optimumfx.com
  • 2. In-Depth analysis tools When you have either a significant one-off defect or problem, or a series of minor problems over a prolonged period of time that requires a detailed approach
  • 3. Benefit of formal problem solving • Think of a typical re-occurring problem that’s worth 60min/week – Fallen bottles on a labeller infeed – Collation errors in a packer – Materials issues in a palletiser – Startup issues following on a Monday morning • Imagine how many hours have been spent observing this issue. How many engineering fixes were attempted. How much money in parts has been spent over the last 6 months that this has hurt you • Now imagine getting a team to sit in an office to work through a structured process for 2-3hr in one go and imagine the most frequent complaint: “This is all very good, but it’s just too slow...we don’t have time for this” • How many hours of resource have you wasted by NOT doing this sooner? • When you have something that’s cost you 60min week for 3 years is 3 hours in one week really too slow?
  • 4. Introduction to a formal problem solving process • As an example of an off-line problem solving process we will demonstrate Kepner- Tregoe’s Problem Analysis process • This is ideal for significant issues or repeat offenders and may involve a team of people for a reasonable period time • Getting a great result = follow the process • Ensure that the team has a trained facilitator who will ensure that the process is followed and that the team are not jumping to unfounded conclusions • Potential issues – A good RCA is a process. A process is only effective when it is followed robustly – Can require strong leadership skills from a facilitator to ensure that the team stays on target
  • 5.
  • 6. Identify possible causes from experience: - Faulty sim card - Phone damaged - Disconnected - Phone not allowed to travel - Flight mode switched on Problem: - I can’t make phone calls Evaluate possible causes: - If_____is the true cause of _____how does it explain the Is and Is Not information? - What assumptions have to be made? - Which cause best explains the Is and Is Not information? CAN SOMEONE HELP ME? IS IS NOT What Object has the deviation Where Is object when deviation occurs When Was deviation observed first Extent How many deviations on obj - My phone - Colleague’s phone - Where I am standing now - The hotel, the airport, conference room - Calling features and data features - At the airport in England - Any other feature on my phone - Since I got off the plane - Continuously - On this trip - Before getting on the plane - All time since getting off the plane - On other trips abroad - 1; my phone - N/a - One; my ability to make calls+data - No trend - All the other phones - N/A - All other applications not working - No trend Define: - My phone can not make calls Problem Analysis Example
  • 8. Bringing it together… 5 Whys Defined problem Refined problem IS/ IS NOT Probably cause Accountability and what happened/when
  • 9. History What’s changed Possible causes Action tracker for each stage of the problem solving process