Structured problem solving methodology,Tools and Techniques

Structured
Problem Solving Methodology,
Tools and Techniques
(Basic version)

www.winningmindssolutions.com
• Need for Structured Problem solving Culture in organization
• Steps in structured problem solving methodology
• Tools and Techniques in problems solving methodology
• Challenges in implementing problem solving culture in SME organization
• Case study examples(on request)
Learning Objectives…

Typical scenario in SME organization

Typical behaviors on problem solving in SME organizations
 Not realizing the problem or trend
No structured, authentic data from shop floor or workplace
 Once problem is realized, jump to quick solutions
 Same issue is cropping up frequently
 Busy in firefighting. “somehow” resolving issues
Hesitate to conclude the options
 No facilitation on arriving solutions

Defining “Problem”

Desired Status
Current Status
Gap =Problem

Hence ,
Problem need not be only quality issues,
it can be anything like
poor sales performance , delivery shortage, manpower absenteeism etc

PROBLEMSPROBLEMS
Hidden root
causes!
People make mistakes
Part Failures / wrong specification
Poor Equipment reliability
Inconsistent in process
Communication Issues
a problem is just tip of the iceberg!

Types of causes for a problem

Which cause must to be addressed ?

• accepted as a way of doing business
• spending most of the time addressing the problem
• happens so often we know exactly what to do in order to quickly correct the problem
• little effect over a short term period, large effect over a long term period
Common Cause Problems

• not accepted as a part of doing business
• must be addressed immediately
• happens on rare occasions
• requires a great deal of time, effort, and resources to correct
• has a high short term effect and a low long term effect.
Special Cause Problems

Hours
Special cause

Essence of problem solving approach
More you do PDCA ,Less Problems

Steps in problem solving

Identify
Data collection
and
Prioritization
Root cause
Analysis
Action Plan Trial
Check against
target
Standardize
Steps in problem solving methodology

17
Step 1. Identification of problem

Identification of problem
 Select the problem based on
Severity
Cost
Customer Service
 Form a cross functional team
Define problem statement and set improvement Goal

Step 2. Data Collection & Prioritize

It requires
Time
 Detailing
Unbiased
Data collection

Tools for data collection
Check sheet

A check sheet is a paper form on which item to be checked have been
printed already so that data can be collected easily and concisely.
Purpose of check sheet
1) To make data-gathering easy ;
2) To arrange data automatically so that they can be used easily later on
To collect data in a systematic and simple manner method
Check sheet

Check sheet Example
Utilization factors Shift 1 (Time in
Min)
Shift 2
(Time in Min)
Machine breakdown 70 90
Tool setting 68 56
Material not available 87 57
Operator not available 42 90

AM PM AM PM AM PM AM PM AM PM AM PM
C
B
1
2
C C
C B
C
B C C
1
2
A
B
Fri Sat
Equipment Operator
Mon Tue Wed Thu
B-Blow holes C –Crack
Check sheet Example

Tools for Prioritization
Stratification
Pareto diagram

Stratification
consolidation of data into family or group so that we know the macro view of the
situation

Stratification example
0
10
20
30
40
50
A B C D E
PowerConsumption%
Process Area
Power Consumption Process Area Wise
12%
32%
25%
5%
26%

Prioritizing based on data pattern

Strain 104 104 52 52
Scratch 42 146 21 73
Pinhole 20 166 10 83
Crack 10 176 5 88
Stain 6 182 3 91
Gap 4 186 2 93
Others 14 200 7 100
Total 200 - 100 -
Cumulative
Percentage
Type of
Defect
Number of
Defect
Cumulative
Total
Percentage of
Overall Total
Data sheet for pareto

A : Crack, B : Scratch, C : Stain, D : Strain, E : Gap, F : Pinhole.
No
of defectives
Examples of Pareto Diagram
42
20
10 6 4
14
104
52
100
939188
83
73
0
20
40
60
80
100
120
140
160
180
200
D B F A C E Others
0
10
20
30
40
50
60
70
80
90
100
Percentage
defectives

Step 3. Root cause analysis

Process:
List out all
Possible Causes
Find out the
Probable Causes
Brain
Storming
Find out the
Root Causes
Verify the Possible
Causes
Verify the Probable
Causes

 Gather all relevant people together
 Get opinion / ideas for the problem from each person
Do not criticize or neglect anyone‘s opinion / idea
List down all the opinion / ideas
Brain storming process :

Example of Cause and Effect Diagram
MAN
Motor not
Working
MATERIAL
Improper Fixing of
Bracket Brake strap
Assembling With out
Spring
Wrong setting of
Torque in Drivers
Driver used for Fixing
Tub and under
base
METHOD MACHINE
Driver used for
Tightening Motor
Driver used for
Tightening Brake Drum
Driver used for
fixing brake fix plate
Tightening of
Brake Drum
Tightening of
Motor Assembly
Brake strap Length variation
Brake Drum OD
Actuator
length variation
Bracket Brake thickness Variation
Lid Bracket ID
variation
Spring Stiffness Variation
Spring length Variation
Spring Stiffness Variation
Brake Sleeve Length VariationAssembling of wrong
motor
Tightening of
Brake fix Plate
Tightening of
Lid Switch in Timer Bracket
Assembling of Bracket Brake
strap in Wrong Hook Position
Assembling of wrong spin timer
Brake Drum OD
Brake Drum ID

Validation of each POSSIBLE causes by checking against
STANDARDS or in ACTUAL WORKPLACE

S
S
S
S
S
Possible causes
Probable causes

Why–Why Analysis

Ask Why?
To get ROOT CAUSE of the problem
 Who?
 What?
 When?
 Where?
 Why?
 How?

Ask Why? Answer
Replace worn chain
( 7) Drive chain failures
Root Cause &
Solution
Why chains failing? Drive chain wears
& breaks.
Why do drive
chains wear &
break?
Sprockets are worn Replace sprocket
Why are sprockets worn? Bearings are worn Replace bearings
Why are bearings worn? Broken grease line Replace line
Why was the line
broken?
Broken during
cleaning
Reroute the line
so it cannot be
damaged.
Example “Why Why Analysis”

Step 4. Action Plan

 prepare action plan with
•Clear actions ( short term and long term)
•People responsible for deliverables
•Timeline specific
Preparing Action Plan

S.No Category Causes / issues Action Description Completion
Target
Resp
1 Utilization Setting time > 3
hrs
Implement SMED
in press to reduce
to 2 hrs
3rd
jun’16 Vinoth
2 B/d : Avg 5 hrs Ensure availability
of critical spare
16th
Jul’16 Vivek
3 Efficiency Low manpower
output
Train on loading /
and Multi comp
loading
17th
May’16 Vasu
4 Quality 2% Rejection in
Grinding
Change wheel
once in 1000 no’s
immediate suresh
Example of Action Plan
Can you identify the RIGHT & WRONG practices in above examples ?

Making RIGHT ACTION PLAN is Management SKILL

Challenges in preparing action plan :
Uncertainty
Risk Taking
Business sense
Decision making
One of the essential management skill to be learnt

Step 5. Conducting Trial

• Implement in small batch or in Pilot area
•Validate the assumptions
•Look for any other side effects
Process of Conducting Trial

Step 6. Check Result against Target

709
662
330
273
376
275
250
400
550
700
Jan Feb Mar Apr May June
Month
QtyProduced
Production Trend
Example of checking using line graphExample of checking using line graph

3.4
3
4
6.3
4
7
0
1
2
3
4
5
6
7
8
9
10
Jan Feb Mar Apr May Jun
HrsExample of Checking using Bar Chart :Example of Checking using Bar Chart :
Month
Equipment break down hrs Trend

Step 7. Standardization

 Revise / Update design documents
Horizontal applications
SOP’s
Standardization process

Thank you for your Interest
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For Business / Life Excellence articles and case studies
pl visit website : www.winningmindssolutions.com

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