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By:Rajesh Sahasrabuddhe

WHAT IS “PROBLEM ” ?

“PROBLEM” means…….• Your part is not as per specification ?• Your process is not in your control?• Your internal rejection % is very high?• Your delivery performance is less than

100 %?• Your external rejection % is very high?• Your waste % is very high?

etc……….

You want to solve problem…..

• Temporarily…..or

• Permanently……• And become problem

solver

Have got Problem ?Do what you can, where you are and

with what you have got.

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Knowledge

So what to do…..?

There are ways and techniques for solvingeach and every problem but the urge forsolving, make these techniques powerful.

Because………..

Even to the hardest problems... Just Urge to solve it…

So how to do it……? Solve the problems such that…

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So let us know types of problem solvingtechniques………

? ? ? ?1 2 3 4 …..

1. Define the problem

2. Build a Team

3. Containment action

4. Determine the root cause

5. Verify the root cause

6. Corrective Action

7. Preventive

8. Congratulate the Team

And Many others……P

Why use this approach…..?

• This technique has proven itsusefulness in other companies

• Common methodology –everybody understands how

• Focus on Fixing it - first time right• Define priorities• Sharing the lessons learned with

others

When do we use this technique……….?• Significant or repetitive complaints• Repetitive human errors occurring during

a specific process• Repetitive equipment failures associated

with a specific process• Performance is generally below desired

standard• ...

Major impact or Repetitive issues

This technique is based on……….

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How does the technique in moredetail look like……….?

1… Clarify the problem2… Break down the problem3… Target Setting4… Determine Root Cause5… Develop Countermeasures6… See Countermeasures through7… Confirm Results & Process8… Standardize process - Sustain the gain

How to fit PDCA with this technique…?

Problem Solving Guide…

Let us take Step : 1- Clarify the Problem

• What do you understand by the problem ?• What is exactly the problem is ?• How you define the problem ?• Is problem the gap between desired and

actual ?• What is and how is affected by the

problem – How you say it is a problem ?

Problem Solving Guide…

Step :1 Clarify the Problem

Desired / IdealSituation

Actual / CurrentSituation

Gap = ProblemGap = Problem

• What we understood is problem means “GAP”

between desired and actual situation.

• Now also identify who is getting affected by

Problem, what is the cost, what is priority etc….

Step :1 Clarify the Problem

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Step :1 Clarify the ProblemLet us take type of problems in easy wayType 1 : Standard not achieved

The Standard = 100 % on time delivery

Actual = 82 % on time delivery

15.50 mm

Requirement is 15.75 ± 0.1mm

( 15.65 to 15.85 mm)

Step :1 Clarify the Problem

Type 2 : Standard is achieved but a higherstandard is required now

Actual 100 % on time delivery @ 2week lead time

New standard 100 % on time delivery @1 week lead time

Now new higher standard is target….

Step :1 Clarify the Problem

Type 3 : Consistency in the achievingresult is not there

Time

The standard

Actual

Step :1 Clarify the Problem

Step 2: Break down the problem Step 2: Break down the problem

Problem ( Complex )

Problem

Problem

ProblemProblem

Problem Problem Problem ProblemProblem

Break Down

Break Down

Break DownAsk questions like why, where,

when ,who etc…

Prioritized problem

Point of Cause

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• Requires to study the process to detail• Dedicate sufficient time for the breakdown• Study the steps of the process, interact with

people, get data, documents, understand tools:Learn

• All problems can be divided into smaller definedproblems: by region, location, department,product, channel, customers, etc.

• Specify the point of cause: the problem is presentin a specific part of the process

Step 2: Break down the problem Step 2: Break down the problem

Step 3: Target setting Step 3: Target setting

What are GOOD and BAD targets …….?

• When you set the target you should bevery specific about the requirement ordesired result of the actions you are goingto take.

• What• When• Where• How much

Step 3: Target setting Step 4: Determine root cause

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Step 4: Determine root cause

Followings are the ways of finding root cause…….

• A team is require to do this activity• Please note that any thing come in

mind as a cause you should write• DO not criticize anybody for silly

thought• Do not get trapped by your own train of

thinking• Note down all the thoughts came from

team’s mind

Step 4: Determine root causeBrainstorming

Step 4: Determine root cause

Pareto’s principle says you should attackfirst on the cause which are affecting 80%

Pareto AnalysisStep 4: Determine root cause

Fishbone Diagram

Step 4: Determine root causeFishbone Diagram

Problem :

We startfishbone

diagram withproblem

statement

Man Method Material

Machine Measurement Environment

Then we willadd Headers

Then more causes added as smallerbranches

Markproblem if

proved

• Try to make your effect measurable– Can you plot graph for the effect ?– Can you calculate the figures for effect ?

• Sometimes ‘6M’s’ can be replaced withrequired headers like :

– Policies– People– Procedures– Plant (Facility)– Programs (Software)

Step 4: Determine root cause

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5W1HStep 4: Determine root cause

Example 01Step 4: Determine root cause

Example 02Step 4: Determine root cause

5W1HStep 4: Determine root cause

Step 4: Determine root causeCheck sheet

• Visualization of measurements• Upper & lower specification

limits + mean• Location of measurements

helps analysis

Step 4: Determine root causeControl charts

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Step 5: Develop countermeasure Step 5: Develop countermeasure

Step 5: Develop countermeasure Psychology of Countermeasures

Step 6: See Countermeasure Through Step 7 : Confirm Results & Processes

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Step 8 : Standardize process Step 8 : Standardize process

Kaun Banega Carodpati Question No. 1

Answer

None of the above, All are valid

Question No. 2

After identification of actionable root cause

Answer

After identification of actionable root cause

All of the above are steps in the Problem-Solvingprocess

Answer

Question No. 3

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Question No. 4

Any Question

THANK YOUfor your patience