Problem Solving Tools
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– MSA – Isoplot – Gage R&R Studies
Some tools to verify solutions are:
– Single Factor Confirmation – Full Factorial Experiment – Process capability analysis
Prepared by Steven Schafer, September 16, 2009
5. Plan and Implement Permanent Solution
The focus of this process is to plan and implement the solution into production. Things to consider in the planning stage are:
– – – – – Check Sheets Pareto analysis Control charts Plant returns FTQ charts
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking Note 2: For other column headers see Figure 2.1 on last slide
– – – – – – – – – – – – – – – – – – – – – – – – – – – Cause and Effect Diagram / Fish Bone Diagram / Ishikawa Diagram Flow Chart / Diagram / Arrow Analysis Run Chart Histogram Pictograph / failure concentration diagram Control Chart Brainstorming Gantt Charts Rings of Influence Consensus 5 Why’s / Why-Why diagram Multi-vari Component Search Pair Comparison Nominal group techniques Tabular arrangement Force Field analysis Affinity diagram Interrelationship diagraph Program decision process chart Matrix Check list / sheet Pareto analysis Ranking Process Mapping Scatter Plots Tree diagrams
6. Verify Solution is Effective
The focus of this process is to ensure that the solution truly eliminates the reappearance of the problem. This is accomplished by using tools that collect and analyze data, such as:
1. Problem Definition
2. Determine Possible Causes 3. Failure Cause Investigation 4. Select and Verify Solution 5. Plan and Implement Permanent Solution
– – – – – – – – Error Proofing Preventative maintenance PCP DFMEA / PFMEA Operator instructions Visual aids Design changes Standardize
Prepared by Steven Schafer, September 16, 2009
Prepared by Steven Schafer, September 16, 2009
2. Determine Possible Causes
This process consists of listing all the possible causes that could contribute to the problem. Clue generation:
Prepared by Steven Schafer, September 16, 2009
4. Select and Verify Solution
The focus of this process is to select a solution that will “Kill” the problem, that is eliminate the possibility of the problem from occurring in the future. Verify the measurement system:
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking Note 2: For other column headers see Figure 2.1 on last slide
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking Note 2: For other column headers see Figure 2.1 on last slide
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
6. Verify Solution is Effective
Prepared by Steven Schafer, September 16, 2009
1. Problem Definition
Before one can start the Problem Solving Process, the problem needs to fully understood. This description should include: – Where the problem occurred – Under what conditions was the problem observed – Extent of the problem (100%, one out of 7, etc.) – Anything else that adds to the knowledge of the problem. The problem has been fully defined once you can no longer come up with additional questions you need answered to understand the Problem.
– – – – – – – – – – – – – – DOE Tools Solution Tree / Fault Tree Analysis Formal experimentation Study of worker methods Correlation Piece-to-Piece variation Within piece-to-piece analysis Stream-to-Stream analysis 5 Why’s / Why-why diagram Run Charts Histograms B vs W (BOB vs WOW, Best Of the Best vs Worst Of the Worst) Autopsies What can the parts tell us
Problem Solving Tools
Prepared by Steven Schafer, September 16, 2009
Generic approach to Problem solving
Problem Solving can be broken up into 6 basiቤተ መጻሕፍቲ ባይዱ steps:
Prepared by Steven Schafer, September 16, 2009
3. Failure Cause Investigation
The focus of this process is to determine the true Root Cause. If the process that creates the problem is complex and has many parameters / factors that can influence the outcome, then more complex tools , such as, DOE might be needed to arrive at an understanding of what combined factors are causing the problem. Some tools that help arrive at the root cause are:
Some tools to verify solutions are:
– Single Factor Confirmation – Full Factorial Experiment – Process capability analysis
Prepared by Steven Schafer, September 16, 2009
5. Plan and Implement Permanent Solution
The focus of this process is to plan and implement the solution into production. Things to consider in the planning stage are:
– – – – – Check Sheets Pareto analysis Control charts Plant returns FTQ charts
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking Note 2: For other column headers see Figure 2.1 on last slide
– – – – – – – – – – – – – – – – – – – – – – – – – – – Cause and Effect Diagram / Fish Bone Diagram / Ishikawa Diagram Flow Chart / Diagram / Arrow Analysis Run Chart Histogram Pictograph / failure concentration diagram Control Chart Brainstorming Gantt Charts Rings of Influence Consensus 5 Why’s / Why-Why diagram Multi-vari Component Search Pair Comparison Nominal group techniques Tabular arrangement Force Field analysis Affinity diagram Interrelationship diagraph Program decision process chart Matrix Check list / sheet Pareto analysis Ranking Process Mapping Scatter Plots Tree diagrams
6. Verify Solution is Effective
The focus of this process is to ensure that the solution truly eliminates the reappearance of the problem. This is accomplished by using tools that collect and analyze data, such as:
1. Problem Definition
2. Determine Possible Causes 3. Failure Cause Investigation 4. Select and Verify Solution 5. Plan and Implement Permanent Solution
– – – – – – – – Error Proofing Preventative maintenance PCP DFMEA / PFMEA Operator instructions Visual aids Design changes Standardize
Prepared by Steven Schafer, September 16, 2009
Prepared by Steven Schafer, September 16, 2009
2. Determine Possible Causes
This process consists of listing all the possible causes that could contribute to the problem. Clue generation:
Prepared by Steven Schafer, September 16, 2009
4. Select and Verify Solution
The focus of this process is to select a solution that will “Kill” the problem, that is eliminate the possibility of the problem from occurring in the future. Verify the measurement system:
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking Note 2: For other column headers see Figure 2.1 on last slide
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking Note 2: For other column headers see Figure 2.1 on last slide
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
6. Verify Solution is Effective
Prepared by Steven Schafer, September 16, 2009
1. Problem Definition
Before one can start the Problem Solving Process, the problem needs to fully understood. This description should include: – Where the problem occurred – Under what conditions was the problem observed – Extent of the problem (100%, one out of 7, etc.) – Anything else that adds to the knowledge of the problem. The problem has been fully defined once you can no longer come up with additional questions you need answered to understand the Problem.
– – – – – – – – – – – – – – DOE Tools Solution Tree / Fault Tree Analysis Formal experimentation Study of worker methods Correlation Piece-to-Piece variation Within piece-to-piece analysis Stream-to-Stream analysis 5 Why’s / Why-why diagram Run Charts Histograms B vs W (BOB vs WOW, Best Of the Best vs Worst Of the Worst) Autopsies What can the parts tell us
Problem Solving Tools
Prepared by Steven Schafer, September 16, 2009
Generic approach to Problem solving
Problem Solving can be broken up into 6 basiቤተ መጻሕፍቲ ባይዱ steps:
Prepared by Steven Schafer, September 16, 2009
3. Failure Cause Investigation
The focus of this process is to determine the true Root Cause. If the process that creates the problem is complex and has many parameters / factors that can influence the outcome, then more complex tools , such as, DOE might be needed to arrive at an understanding of what combined factors are causing the problem. Some tools that help arrive at the root cause are: