Problem Solving Overview

www.optimumfx.com

Intent of session

• This session will enable you to:

– Identify which problem solving techniques are best applied in your plant

– Know when the most appropriate technique can be applied to get maximum result

– Evaluate complex decision options and always make a decision that’s based on transparent logic

Why formalise problem solving?

• To ensure that issues get resolved right first time – saving time and money

• It starts to remove the “hero saving the day” mentality – only core individuals know how to fix issues– without formalised problem solving you will always have ‘heroes'.

• To massively reduce the risk of damaging your people, product, and assets by implementing incorrect actions

• To ensure that the most appropriate technique is applied to get the best result – one size does not fit all holes!

Convergent Vs Divergent thinking• Convergent processes

• Divergent processes

Lots of ideas or opinions

Convergent process

A specific problem or

issue in time

Divergent process

Create many different

options for action

Identify one specific action

Types of process:- Any process that funnels your thinking- Decision Analysis- 5 Whys

Types of process:- Any process that creates ideas- Brainstorming- Vision creation exercises

Root Cause Analysis Tools

Problem Root Cause Corrective actions

Root Cause Analysis Tools- 5 Whys- Ishikawa Charts (Fishbone)- Is/Is Not Analysis (Kepner-Tregoe)- Statistical data analysis

Types of problem solving process

• So many tools so little time– There are many problem solving tools available and all are based on the same

principles. – We’ve chosen a couple of tools to get you started

• Pick one tool and use it regularly– All learning behaviour is unconscious – we learn from repetition– Just pick a tool that seems best for you and commit to using it regularly >once a day– The more tools you try the less likely you are to make any of them work really well

• Simple tools for use on smaller or less complicated issues:– 5 Whys, Ishikawa (fishbone) diagrams

• More in-depth tools for handling complex or repeat issues.– E.g Kepner-Tregoe (KT) Problem Analysis

Before you start: - Define your problem

• This first step is critical – a poorly defined problem will result in hours of wasted effort

• Make sure you define the problem with great clarity and precision.– The more weak your problem definition, the lower your likelihood of solving it

• To define a problem consider creating a sentence with this structure:

• What object(s) has the deviation? What deviation does it have? What do we see, hear, feel, taste, or smell that tells us there is a deviation?

• E.g. The bottles on the outfeed of labeller 2 on line 2 have 10 bottles every minute with glue but no labels applied.

Picking the right tool for the job

Quick and easy

Detailed and robust

Large problem

Small problem

5 Whys

May be an individual or team event

Can be highly subjective and unrepeatable.

Ideal for providing structure for highly skilled individuals

Ishikawa/ Fishbone diagrams

Live on-going process for teams or individuals with defined outcome

Makes possible cause transparent through online documentation

Ideal for providing a structured approach for every day issues

Formal RCA process

Global 8D

KT Problem analysis

Typically an off-line analysis event

Highly transparent and replicable – will guide team to find new

knowledge rather than rely on existing

Ideal for tackling and closing complex issues

Problem Analysis Conclusion

• There are a range of problem analysis tools very quick and relatively subjective tools, to more involved and analytical tools

• Pick the right level of tool to fix the level of issue that is occurring

• Convergent processes – Narrow down choices• Divergent processes – Create ideas

• It’s better to have one tool that you use at expert level than 10 tools you don’t use at all

• Define your problem with a clear and concise problem statement that is based on real evidence

• Complex problems may require significant time and personnel investment to solve....many people are so keen to act that they won’t invest 3hr to solve an issue that’s been unfixed for weeks or years