Problem-solving

By Sandeep Gaje -

Problem-solving :

It involves a structured approach to identify, analyze, and resolve production issues.



5 C's of problem-solving:

The 5Cs are 

1)Conditions, 

2) Correlations, 

3) Contributions, 

4) Causes, and 

5) Corrections.




Problem-Solving Techniques:

  1. Trial and Error: Testing different methods for a solution to problem.
  2. Lateral Thinking:  Using unconventional approach or angles for  the problems.
  3. Divide and Conquer: Breaking down large/complex problems into smaller/manageable parts.
  4. 5 Whys: Ask "why" repeatedly to find out the root cause.
  5. Fishbone Diagram : Visually mapping out  causes of a problem to identify root issues. Also known as 'Ishikawa'.
  6. Working Backwards: Starting with the desired final result and work backward to determine the steps required to reach desired result.
  7. SWOT Analysis: By evaluating the Strengths, Weaknesses, Opportunities, and Threats related to a potential solution.
  8. PDCA Cycle (Plan-Do-Check-Act): A four-step  method for continuous improvement.
  9. Take a Break: Stepping away from a problem can allow the mind to reset, fostering unexpected solutions.

Important Techniques of Problem Solving:

  • TRIAL AND ERROR
  • BRAINSTORMING
  • ROOT CAUSE ANALYSIS
  • WORK BACKWARDS
  • SWOT
  • PARETO
  • WHY WHY HOW ANALYSIS
  • FISH BONE DIAGRAM
  • PDCA

Listen for Team:

  • Explore by asking questions
  • Affirm to show you're listening
  • Reflect your understanding
  • Silence (listen some more)
  • Collaborate with Empathy

Tools for Quality & Problem Solving

1) Jidoka :  
It is the principle of designing equipment to stop automatically when a defect is detected. In a one-piece flow, this prevents a defect from multiplying, as the problem is exposed and fixed immediately at the source.
Jidoka is the idea that manufacturers should design equipment to partially automate the manufacturing process and to automatically stop when defects are detected.
Workers can frequently monitor multiple stations.
Many quality issues can be detected immediately.

2) Andon: 
A visual feedback system like lights, horns, or displays as alerts.
Andon is a visual feedback system.
Andon on shop floor indicates production status. On contineous process line it gives alert to operators or support team or supervisor to stop the production process. It gives alerts so that one can approach to the place where assistance is needed instantly and can be easily  addressed. Thus Andon acts as a real-time communication tool.

3)  Poka-Yoke (Error Proofing): 
Devices or design features implemented in the workstation that physically prevent human errors or make them immediately obvious, ensuring zero defects flow downstream.

4) Standardized Work: 
Clear documentation, repeatable procedures for each task. It defines the specific work sequence, standard operating processes, standard cycle time, and standard amount of work in progress inventory (WIP), ensuring variation is kept to a minimum or zero defect.

#
Location: India

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