Problem Solving

(PDCA)

Definition of a Problem ?
A problem is defined as:
The discrepancy between the current situation
and the standard for that situation
A standard is a specific established KNOWN
expectation of what should be for a given
situation
The current situation is the way things are now
A discrepancy is a measurable or quantifiable
difference between a standard and the current
situation

Prioritizing Problems Cont.

,
Business
Business // Operational
Operational Problem
Problem

Effects on each
could Result

Cost

Delivery

Quality

Safety

Importance Urgency Occurrence

3

Have I the correct

Attitude to solve
problems?

Who did this???

A
A failure
failure is
is just
just the
the
tip
tip of
of the
the iceberg!
iceberg!

Failures

Unplanned
Delay

Mismanagement
Unskilled/ Untrained
Negligence
Wastes

Break Downs

Hidden
Conditions/
Causes

Think !!!!!!!

A problem is an opportunity to improve

Problem Perception
WITHOUT DATA YOU ARE JUST ANOTHER PERSON WITH AN
OPINION

(You cant manage what you arent measuring.)

Problem Solving Tools

When you only have a hammer in your tool box

..
Suddenly every problem looks like a nail

What are the Tools ?

Brainstorm & Affinity
Process Flow Charts
Check Sheets
Cause & Effect (Fishbone)
Histogram & Pareto
Scatter Diagrams &
Measles Charts
Control Charts

Example
Analysis of end line defects

Man

Mother
Nature

Loose threads

Uncut
thread
s

Out of
shapes

MateriFabric Defects
al

Stains

Open
seam

Dust

Wrong stitch
density
Seam
puckering
Oil marks

Wrong thread
tensions

Skip stitches

Machin
e

Defects
at end
line

Measurement
problems due
to use of
wrong
equipment or
patterns

Method

Measure
ment
problem
s due to
cutting
issues

Histograms

Graphically shows how many times different events happen

Example :
Measles Chart Garment Defects

Example
Control Chart with Violations

UCL

LCL

Yield

Example
SPC Chart Out of Control

UCL

LCL

Batches

Using Tools - Everyday

Problem !
Understand it Process Flow Charts
Identify Effects Data Collection
Identify Causes - Brainstorming,
Fishbone
Analysis Histogram & Pareto
Fix it- PDCA
Control it Control Charts, Check
Sheets
Monitor Control Charts

PDCA
16

Step 1
Select a team to help ..

Step 2
Define the problem

Remember

Gengi Gembetsu Go & see the

problem your self & thoroughly understand

Step 3
Take Containment action

Problem Solving
PDCA
Plan-Do-Check-Act

PLAN

DO

I. Identify Problem
II. Analyze Cause
III. Formulate

I. Develop Implementation Plan

II. Communicate Plan
III. Execute Plan

ACTION

CHECK

(Adjust)

I. Evaluate Results
II. Standardize Effective
Countermeasure(s) or
Start PDCA again or
Do both if results
`
uneven

I. Monitor Progress of
Implementation Plan
II. Modify Plan if Necessary
III. Monitor Results

Problem Solving
PDCA
Plan-Do-Check-Act

The PLAN Phase

Identify the problem
Analyze the cause
Formulate

The DO Phase
Develop a plan to implement countermeasure(s)
Communicate the plan (to anyone who may be able to provide
additional input or who may be affected by the plan
Execute the plan

Problem Solving
PDCA
Plan-Do-Check-Act

The ACTION (Adjust) Phase

Evaluate results AND

Standardize effective countermeasure(s) to prevent recurrence OR
Start the Plan-Do-Check-Action process again to achieve target/goal
OR
Do both if your results are uneven

The CHECK Phase

Monitor the progress of the implementation plan
Modify implementation plan if necessary
Monitor the results

Problem Solving
PDCA
Plan-Do-Check-Act
Theme

Problem Situation
Standard
Current Situations
Discrepancy
Extent
Rationale

Targets & Goals

Do What
How Much
When

Cause Analysis
Do What
How Much
When

Step 4
Define & Verify root causes

Identifying potential causes

Challenging those potential causes
Making reasonable assumptions about the
most likely cause of the problem
Investigating to get the needed facts while
continually asking Why?

Work backwards from the root cause to the problem

statement saying Therefore between each Why?
statement

If you can proceed logically from the last Why?

statement to the problem statement, the process was done
correctly

Problem Solving
PDCA
Plan-Do-Check-Act

Countermeasure(s)
Short Term
Long Term
Why Recommended

Implementation
What

Where

Who

When

Follow-Up
What

Where

Who

When

Step 5
Verify corrective actions

Effective use of tools & PDCA Techniques

+
Effective Team Working
+
Effective Facilitation
=
Maximum Success !

Thank You