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.
DAY TWO
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.
DAY THREE
Root Cause Analysis
Introduction
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
Train
Start audits
Transfer knowledge
Lesson 5
Overcoming Barriers 10 barriers to Root Causes Analysis with potential remedies
Challenge
(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
Methodology
• Psychological games
• Role plays
• Case studies
