Critical Problem Solving

Problem solving is a comprehensive, computer-based interactive training system that teaches employees how to use proven problem-solving techniques to improve manufacturing quality and productivity.
Course Objectives
Learners will be able to:
1.    Understand and use the 8-Discipline process to solve problems.
2.    Work on and contribute to a problem-solving team.
3.    Apply the appropriate problem-solving tools throughout the problem-solving process.

Day One

Lesson 1
Becoming Aware of a Problem                                          Ways to recognize indications of problems.
                                                                                     Ideas to help decide which problems to work on first.

Lesson 2  
Why Use a Structured Problem-Solving Process?                 How a formal problem-solving approach can improve the effectiveness of the whole                                                                                     organization.
                                                                                     Building a common problem-solving language.

Lesson 3
Do You Need a Team?                                                     Five questions to determine which problems need a team and which problems one                                                                                     person working alone can effectively handle.

Lesson 4
The Importance of Data                                                  How data leads to information and information points the way to knowledge.
                                                                                    Subjective versus objective data.
                                                                                    Attribute data versus variable data.
                                                                                    Using data to infer and make judgments.

Lesson 5
Different Problem-Solving Models                                     8-Discipline Problem-Solving Model
                                                                                     DMAIC Project Cycle
                                                                                     Xerox Problem-Solving Process
                                                                                     Boeing Process Flow for Working Projects
                                                                                     A generic Six-Step Problem-Solving Model

Unit Test
Problem-Solving Challenge                                                 An assessment of the learner’s progress in this unit.

8 Discipline Process

Lesson 1
Use a Team Approach                                 Establishing team membership, roles of the members, boundaries of freedom for the team, and                                                                 getting the team started up.

Lesson 2
Describe the Problem                                  Developing the Problem Statement.

Lesson 3
Interim Containment                                    Designing and putting temporary measures into place and verifying that they are working.

Lesson 4
Define the Root Causes                                 Using a systematic approach to collect, display, and analyze data to identify the root cause(s).
                                                                  Verifying that the cause identified is truly the root cause.

Lesson 5
Develop Solutions                                         Finding a solution to attack the root cause and correct the problem.
                                                                  Using mistake-proofing techniques.

Lesson 6
Implement the Solution                                  Developing simple and complex action plans.
                                                                    Using Gantt and PERT Charts to plan the implementation and monitor progress.

Lesson 7
Prevent Recurrence                                       Finishing the job to ensure the problem does not come back.
                                                                   Ensuring training, audit practices, and knowledge transfer are completed.

Lesson 8
Congratulate the Team                                    Providing recognition for the problem-solving team.
                                                                    Ensuring the problem-solving team recognizes those that have assisted them.

Unit Test
Problem-Solving Challenge                                An assessment of the learner’s progress in this unit.


Root Cause Analysis

Root Cause Analysis Overview                                 Overview of Root Cause Analysis
                                                                            Preview of Lessons 1 through 4

Lesson 1
Form & Focus the Team                                           Form a Team
                                                                             Focus the Team
                                                                             Understand the Problem

Lesson 2
Find the Root Cause                                                 Create a cause & effect diagram
                                                                             Explore chains of causes
                                                                             Study interrelationships
                                                                             Use data analysis & investigative tools
                                                                             Identify root causes

Lesson 3
Fix the Root Cause                                                    Propose potential solutions
                                                                             Select the “best” solution
                                                                             Conduct a reality test
                                                                             Develop Action Plan to implement solution
                                                                             Verify the solution

Lesson 4
Finalize the Solution                                                 Validate the solution
                                                                             Update documentation
                                                                             Start audits
                                                                             Transfer knowledge

Lesson 5
Overcoming Barriers                                             10 barriers to Root Causes Analysis with potential remedies

(Course Test)
Root Cause Analysis with Corrective Action Test         An assessment of the learner’s understanding of the body of knowledge.

General Principles of Thinking

Understanding the importance of critical thinking and how it differs
    •         Six critical thinking skills: interpretation, analysis, inference, explanation, evaluation, and self-regulation.
            Right Brain! Left Brain! Brain Sprain!: Understanding Your Preferred Approach
    •         Difference between right-brain and left- brain thinking 

Get out of the Box: Basic Creative Thinking Skills
.  Brainstorming, negative brainstorming, mind mapping, and random words.
    •         Real-world business problems using a variety of ideation methods.

We’ve Always Done It This Way: Getting Past Nay-Sayers and Other Negative People
    •         Overcoming the mentality of "that’s never going to work
    •         Creating new ideas and techniques
    •         Clear framework of decision making process
    •         Mild mapping
    •         Win-Win thinking
    •         Lateral thinking
    •         Six thinking hats
    •         Divergent convergent thinking

•    Psychological games
•    Role plays
•    Case studies