Effective prob. solving technique
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Effective prob. solving technique
- 1. 1 EffectiveEffective Problem SolvingProblem Solving TechniqueTechnique Knowledge is, turning high potential into high performance By:By: Mohd. ShahjahanMohd. Shahjahan
- 2. Anything thatAnything that Deviates from theDeviates from the Standard or TargetStandard or Target What is a “Problem”What is a “Problem” Knowledge is, turning high potential into high performance An unfulfilled customer’s need A Gap between Actual & Desired condition Introduction to Effective Problem Solving Technique
- 3. Negative Variance “Problem” Performance T I M E Look at Problem Diagrammatically Positive Variance “Opportunity” Diagram of a Problem Knowledge is, turning high potential into high performance Introduction to Effective Problem Solving Technique
- 4. Performance Time Negative Variance Problem Look at Problem Diagrammatically X When actual performance started to deviate, Something happened at the time ‘X’ which caused the problem to occur Knowledge is, turning high potential into high performance Introduction to Effective Problem Solving Technique
- 5. What skills are necessary when solving a problem? KnowledgeKnowledge ExperienceExperience Communication SkillsCommunication Skills Grouping SkillsGrouping Skills MotivationMotivation Knowledge is, turning high potential into high performance Introduction to Effective Problem Solving Technique
- 6. How to solve Problems? Knowledge is, turning high potential into high performance A problem WELL DEFINEDWELL DEFINED is a problem half solved Introduction to Effective Problem Solving Technique
- 7. Benefit of Structured Problem Solving Remove time lost in debate Identify weak points in processes Discover systemic causes Explain with reasons why an incident occurred Gives a factual representation of the incident Compare what actually happened against what should have happened To ensure Problems don’t Re-occurTo ensure Problems don’t Re-occur Knowledge is, turning high potential into high performance Introduction to Effective Problem Solving Technique
- 8. 8 Steps Problem Solving Knowledge is, turning high potential into high performance Step 1 Identify/Select Problem Step 2 Understand Present Situation Step 3 Identify Root Cause Step 4 Plan Improvement Step 5 Execute Improvement Step 6 Confirm Result Step 7 Standardize Improvement Step 8 Future Plan Introduction to Effective Problem Solving Technique
- 9. The key to a good problem definition is ensuring that you deal with the real problemdeal with the real problem, not its symptoms.not its symptoms. True problem must be understood before action is taken. Problems are often masked forProblems are often masked for a variety of reasonsa variety of reasons Knowledge is, turning high potential into high performance Step 1 - Identify & Select Problem
- 10. Handy question of ‘What’‘What’ When attempting to solve a problem. Questioning Tool Box What is wrong? What did you do about it? What was the result? What happened next? What was their reaction? What are the symptoms? What are their effects? What did you notice first? The list give you a clue how to go about using them Analyzing the Problem Step 1 - Identify & Select Problem Knowledge is, turning high potential into high performance
- 11. Any Improvement or Projects, has to be aligned to Customer Satisfaction and or Business Needs. 1. Management Driven 2.Customer Driven 3.Data Driven The Typical Tools used to Identify or Select the Right Problem Step 1 - Identify & Select Problem Knowledge is, turning high potential into high performance
- 12. 1. Improve Operation Cost 2. Improve Delivery / Project Completion 3. Improve Service 4. Grab more business Step 1 - Identify & Select Problem 1. Management Driven Knowledge is, turning high potential into high performance
- 13. Month Jan Feb Mar Apr May Jun Customer Complaint 6 9 5 7 7 8 Customer Complaint Trend from Jan - Jun Goal = 1 Case/Month Step 1 - Identify & Select Problem 2. Customer Driven (ex: Not meeting Quality) Knowledge is, turning high potential into high performance ExampleExample
- 14. 3. Data Driven Month Jan Feb Mar Apr May Jun RM K 52.0 50.0 55.0 67.0 89.0 91.0 Cost Increasing trend Step 1 - Identify & Select Problem Knowledge is, turning high potential into high performance ExampleExample
- 15. 1 – Identify / Select Problem 2 – Understand Present Situation3 – Identify Root Cause 4 – Plan Improvement P L A N 5 – Execute ImprovementDO 6 – Confirm ResultCHECK 7 – Standardize Improvement 8 – Future Plan ACT Introduction To PDCA Cycle Knowledge is, turning high potential into high performance PP DD CC AA
- 16. Understand the overall process involved and collect data on the specific problem identified. What contributes to “Highest Occurrences” problem and quantify it. Understand Present Situation Step 2 – Understand Current Situation Knowledge is, turning high potential into high performance Recommended Tools: Pareto Diagram Bar Chart
- 17. Metal Bender Breakdown Frequency Prolem Frequency Indexer Jammed 42 Form Angle Out 23 Ejector Error 18 Hydraulic Pressure Drop 11 Machine Hang 8 Total 102 Step 2 – Understand Current Situation Knowledge is, turning high potential into high performance Understand Present Situation ExampleExample
- 18. Calculate the Cumulative Percentage and Construct 80/20 Pareto Chart 10 0 20 40 30 100 80 50 60 40 20 Indexer Jammed Form Angle Out Hyd. Press. Drop M/c Hang Ejector Error Indexer Jammed Pareto Diagram of Metal Bender Top 5 Problem Step 2 – Understand Current Situation Knowledge is, turning high potential into high performance Understand Present Situation ExampleExample
- 19. Goal setting - How to set a Goal? Specific – Clear & Definite Measurable – Quantifiable Achievable – Realistically do-able within the time & resources Relevant – Align Company KRA, Business Goal, Customer Focus Timeline- Clear & Specific deadlines Set SMART Goal Example : Eliminate Indexer Jammed frequency from 42 Occurrence to 0 Occurrence, by Dec 2013 Step 2 – Understand Current Situation Knowledge is, turning high potential into high performance
- 20. Brainstorming Brainstorming Is a technique for generating a list of ideas about an issue. Fishbone Diagram Fishbone Diagram graphic tool used to explore and display opinion about sources of variation in a process Step 2 – Understand Current Situation Problem solving ToolsProblem solving Tools Knowledge is, turning high potential into high performance Pareto Chart Pareto Chart Helps to focus on problems that will have the greatest impact if solved.
- 21. Recommended Tools 1. Brainstorming 2. Fishbone Diagram 3. Why-Why Analysis How to identify the Root Causes of the Problem 1. Identify and gather helpful facts on the causes of the problem 2. Confirm opinion on root causes with data, whenever possible Step 3 – Identify Root Caused Knowledge is, turning high potential into high performance
- 22. Causes & Effect Analysis for Indexer Jammed Indexer not assemble correctly Stopper Low Hardness Belt Low Quality Bearing jammed Index Motor Out Stopper Ware off Motor Belt Broken Step 3 – Identify Root Caused Indexer Jammed Man Method Machine Material Did not perform servicing Wrongly assemble Wrong mounting screw used Screw not tighten properly Mounting screw loose ExampleExample
- 23. a) Plan the change process. Ask questions starting with: • What? • Who? • When? • Where? • How? Step 4 – Plan Improvement Knowledge is, turning high potential into high performance b) Do contingency planning when dealing with new and risky plan
- 24. Brainstorm on the Workable solutions to curb the problem Root Caused Containment Action Category : Machine Replace Ware Off Stopper Long Term ActionStopper Ware Off Fabricate new Stopper with different hardness for long lasting Step 4 – Plan Improvement • Consider: How to eliminate the root causes • Use creativity techniques to generate large number of ideas Knowledge is, turning high potential into high performance ExampleExample
- 25. Work out solution for potential risks Root Caused Containment Action Responsible Target Disadvantage Potential Solution Category : Machine Replace Ware Off Stopper Ronie WW 10 Potentially will Ware Off Long Term Action Responsible Target Disadvantage Potential SolutionStopper Ware Off Fabricate new Stopper with different hardness for long lasting Ronie WW 16 Nil, higher hardness will last long Nil Perform Periodic check on stopper Step 4 – Plan Improvement Knowledge is, turning high potential into high performance Evaluate Improvement Actions - Disadvantages/ Risk factors ExampleExample
- 26. Impact & Effort Analysis (Prioritize based on action that give Highest Impact with least Effort) EFFORT High Low HighLow IMPACT #1 #2 #3 #4 Prioritize Action Step 5 – Execute Improvement Knowledge is, turning high potential into high performance High Impact Low Effort Change to Harden Stopper ExampleExample
- 27. Assign task to team members with target completion timeline. Set Timeline Step 5 – Execute Improvement Knowledge is, turning high potential into high performance ExampleExample
- 28. Confirm and establish the methods of monitoring the solution. e.g. : manual data collection / audits Does the solutions have the intended effect? Any undesired consequences? Review / Evaluate the Effectiveness of Improvement Actions Recommended ToolsRecommended Tools 1.1. Bar ChartBar Chart 2.2. Trend ChartTrend Chart 3.3. Pareto DiagramPareto Diagram Step 6 – Confirm Result Knowledge is, turning high potential into high performance
- 29. Construct the Pareto Chart:Construct the Pareto Chart: ““Before” & “After”Before” & “After” BEFORE 10 0 20 40 30 100 80 50 60 40 20 Indexer Jammed Form Angle Out Hyd. Press. Drop M/c Han g Ejector Error 10 0 20 40 30 100 80 50 60 40 20 Indexer Jammed Form Angle Out Hyd. Press. Drop M/c Hang Ejector Error AFTER Step 6 – Confirm Result Knowledge is, turning high potential into high performance ExampleExample
- 30. 1. Documentation (Specification / SOP) Document the system and simplify it so that all users will understand. 2. Proliferation (Best practices are deployed) (at own area, other departments / sites) Reason : - Standardization can help maintain the results and effects of improvement activities being executed. - Develop a training model for standardization (Train existing and new employees) - Audits are necessary to ensure conformance. Two Important Steps at Standardizing Improvement Step 7 – Standardize Improvement Knowledge is, turning high potential into high performance
- 31. 1. Work on the same problem to improve further ( Continual Improvement with higher goal setting ) Repeat the problem solving process 2. Work on the next highest problem 3. Work on a completely new project based on Department / Business needs/ Customer requirement. Team has 3 Options at this Step Step 8 – Future Plan Knowledge is, turning high potential into high performance
- 32. End of Presentation……… Terima Kasih Knowledge is, turning high potential into high performance
Notes de l'éditeur
- welcome speech and self introduction. Share your qualification & experience. Ask participant to introduce themselves. And ask what they expected from this workshop.
- Brief summary of “what is problem:
- The area with the positive variance is called “Opportunity" An opportunity is the exact opposite of a problem. They can be analyzed in the same way as problems. You want to find out what caused an opportunity to happen that you can exploit it to the full or make it happen elsewhere.
- When actual performance started to deviate. Something happened at the time ‘x’ which caused the problem to occur.
- Ex: well define problem -
- Just read thru
- Elaborate as stated
- Give example – car difficult to start in the morning – symptom Reason could be – battery / alternator / starter / fuel pump
- For example- if performance in your dept. is substandard, you might think the problem is with the individuals submitting work. How ever if u look a bit deeper the real prob. might be lack lack of trg or un-reasonable work load.
- Team Activity Each team given a flip chart stand that has the PDCA cycle prepared. Team is also given the 8 cards – 8 steps. Get respective team to arrange the 8 steps in order & paste them in the correct quadrant in the PDCA cycle. Get teams to explain their PDCA cycle, explain why. Will reveal the steps as we go through the course.
- SMART Goal
- The philosophy of brainstorming is quantity breeds quality, the more suggestion, the better. To ensure total participation, everyone has to be given opportunity to speak. Brainstorming is a process of creating a set of ideas for further discussion. It is used to help a group create as many ideas in as short time as possible. The philosophy of brainstorming is quantity breeds quality, the more suggestion, the better. To ensure total participation, everyone has to be given opportunity to speak. Brainstorming can be used in two ways: Structured – in this method, everyone person in a group must give an idea as their turn arises in the rotation or pass till next round. It often even forces shy ppl to participate but also create a certain amount of pressure to contribute. Unstructured – In this method, group members simply give ideas as they come to mind. It tends to create a more relaxed atmosphere but also risks domination by the most vocal members.
- This is the fishbone diagram of the root causes that we have for crack die. Emphasis on grouping the similar points together. Eg: Wafer drop on the floor is a subset of improper handling of wafer.
- Plan the process by asking 4W 1H questions.
- The next step is to establish a corrective action plan to eliminate those causes. Team members should get together to brainstorm as many strategies as possible. Formulate short term (to fix it) & long term solutions (to prevent it). You may evaluate each plan according to the expected magnitude of results. Team should also select a pilot area / machine to start a project. REMEMBER : the pilot area must be small enough so that all the actions can be done very quickly BUT the result that this pilot area gives has to be statistically representatives.
- If there are, work out the solutions for disadvantages / risk factors.
- You may want to use the Impact-Effort Analysis to prioritize action plan (if there are few improvement plans to be executed).
- Set time line for improvement actions, assign tasks among team members so that each action item is carried out in a timely manner.
- ( Once the target results is achieved and stabilized, it is necessary to document those corrective actions that have been found to be effective in controlling the problem. ) There are two important steps in standardizing improvements: First of all is documenting the improvements (Specification or Standard Operating Procedure) Secondly is to proliferate the best practices at own area, other departments as well as across sites. Standardization is implemented to maintain the results and effects of improvement activities that eliminate the true causes of problems. Documentation system must be simplified so that all users will understand. Training model needs to be developed for standardization. Audits are necessary.
- When the improvement plan has been standardized and formally documented, the project is completed. At this stage, the team may choose to disband or work on remaining problems ( as identified in the Prioritization Matrix or Pareto Diagram ) or they can choose to work on a brand new project. If there is still time, share with the team an actual team project that uses the 8 steps of problem solving. ( Shared Learning Forum ) In addition, we can also show the video tape on Problem Solving Technique.