8 Step Problem Solving Method University of Kentucky

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Be adaptable to the work process needs take action. If necessary use TEMPORARY measures,when a problem occurs take action quickly. Keep at it until TRUE countermeasures,are in place. that which if implemented prevents problem from,Speedy Action in a Timely Manner. Difference between Temporary Measure and,Problem Countermeasures. Limit switch,Machine Why,not activated,over travels Fact Limit switch Root Cause.
Arm is Frozen Why,Limit switch is in,Coolant air flow. Temporary measure,Replace the,limit switch,Countermeasure. Prevents the shield limit switch,recurrence from coolant. Temporary Measure Example,Action to stop or contain the problem. can add necessary extra work to the,When a problem occurs take action.
Purpose is to contain the problem not,Temporary Measure. Select the optimal containment action on the,following criteria. Simplicity,Minimal modification to current process. Time to implement,Option 1 Option 2 Option 3,Simplicity 10 8 7 Rate each. Modification 9 10 5 option relative,Time 10 9 7 to each other.
29 27 17 for each,Sum the score and criteria,select the option with. the highest score,Short Term Containment,Identified. Identified,Implemented,Temporary Measure Implementation Plan. A problem is,The current situation gap to the standard PROBLEM. Fact based,Discovery driven,Gap Problem,What Defines a problem in the 8 Step method.
Non Value Added Work Waste,Waste is any factor which does not. contribute to the process by adding,The goal of Lean is to eliminate any. factors which raise cost without adding,value to the product. What Defines a problem in the 8 Step Method,Motion Overproduction. Defects The 7 Wastes,Over Processing Transportation.
What Defines a problem in the 8 Step Method,Would you like to work in this place. What Defines a problem in the 8 Step Method,See normal vs abnormal. Racks and Containers for Small Lot SOP,Andon Cord,Andon Board. Information,Scoreboard,Glasses Foot printing Floor. Walking Aisle,What Defines a problem in the 8 Step Method.
Step1 Clarify the,Step 2 Break Down the,P Step 3 Target Setting. Step 4 Root Cause,Step 5 Develop,Countermeasures,Step 6 See. D Countermeasures,C Step 7 Monitor Both,Results and Processes. Step 8 Standardize,A Successful Processes,8 Step Process for Problem Solving. See handout,Example of Problem A 3 Report,8 Steps Proceedings.
1 Clarify the Ultimate Goal of your responsibilities. Step 1 work,2 Clarify the Standard of your work,Clarify the. 3 Clarify the Current Situation of your work, Problem 4 Visualize the gap between the Current Situation. and the Standard,Step 1 Clarify the Problem, Visualize the gap between the Current Situation and the Standard. 5 The Standard,Visualize the gap,3 between the,2 The Current Situation situation and. the standard,Aug Sep Oct Nov,Step 1 Clarify the Problem.
Process1 Clarify the Ultimate Goal of your responsibilities work. To provide customers with highly functional,Ultimate Goal and high quality cars. at reasonable prices in a timely manner,To meet customer demand. Responsibilities To meet Production Plans,Step 1 Clarify the Problem. 1 Clarify the Problem, Ultimate Goal Assure TMMK cars meet customer requirement for quality. Standard Zero audit defects from sealer area,Current Situation 7 water leaks on 7 28.
Example Step 1,Actual Standard,1 Clarify the Problem. Ultimate Goal TMs are compensated for work completed. and paid timely and fairly,Standard 100 3300 of TM s paychecks are. deposited error free,Current Situation 80 2640 of TM s paychecks. are deposited error free 3300,80 Gap 20 660,20 600 paychecks 0. Need a manual check,To correct errors,Current Standard.
Example Step 1,8 Steps Proceedings, 1 Clarify the Ultimate Goal of your responsibilities work. Step 1 2 Clarify the Standard of your work,3 Clarify the Current Situation of your work. Clarify the problem 4 Visualize the gap between the Current Situation and the. 1 Break down the problem,2 Identify the prioritized problem. Break down,3 Specify the point of occurrence by,the problem checking the process through GENCHI. Step 2 Break Down the Problem,Big Problem What,Problem Problem Problem Who.
Problem Problem Problem Problem Problem Problem Problem. Prioritized,Prioritized Problem at the Point of Occurrence. Step 2 Break Down the Problem,Formulating a clear concise statement. from your Gap,The statement describes the difference. between the standard and current,During this step break the large problem. into smaller more specific problems,If you can t describe it you can t solve it.
Step 2 Break Down the Problem,Narrow the problem sufficiently. Classify and quantify,7 Water leaks,1 on Avalon 6 on Camry Vehicle Type. 1 in Mohican 5 Tail light 1 side Process,Many water leaks in the tail light Prioritized. Priority decision tackle the biggest impact problem FIRST. Step 2 Break Down the Problem,3 increase in,SCRATCHES found on. Classify vehicle at Final Inspection,Then Left 95,Left Roof 0.
Roof Trunk 0,Quantify Right 5,Right Hood 0,Door Door Fender 0. Prioritized,Problem 5 Side,Handle Pnl,Step 2 Break Down the Problem. The point of occurrence POO is the,actual work element at the physical. location where the problem is first seen,For example walk the line back. Check each work station until you,arrive at the station where the problem.
is no longer seen,8 Step Problem Solving,Locate Point of Occurrence. Standard Work,Set seat Align seat Remove Shoot,w carrier to car to rail carrier bolts. POO before Front seat,Scuffed install,Defect was found here Damaged Cup. Holder after,Front seat Back track,Damaged Cup,Holder start. Damaged Cup,Process Holder CSA,Locate Point of Occurrence POO.
Where is Point of Occurrence,Prioritized Problem at the. Point of Occurrence,Why is Point of,Occurrence important. For efficient use of,time effort,Step 2 Break Down the Problem. 2 Break Down the Problem,7 Water leaks,1 on Avalon 6 on Camry Vehicle Type. 1 in Mohican 5 Tail light 1 side Process,Many water leaks in the tail light.
Go and See Investigation for Point of Occurrence,1 Floor Brush Finish lower seam on end panel. Prioritized, 2 Engine Room Finish Finsh the area just above and below the tail light Problem. 1st Engine Engine,Application Room Floor Brush Room. Brush Application,Finish Point of,Occurrence,Finish Hood Finish Rear Finish Finish Finish. Standard Finish Side,Work Corner Hood Mirror Upper end below tail.
tail light,Plate panel light,Example Step 2,Point of Occurrence. 2 Break Down the Problem,20 660 3300 manual checks being issued. Group Leader Error Other Salary Continuation,35 231 660 23 151 660 42 277 660. Time Execution Other STD Not Paid FMLA PTO Not Paid. 61 142 231 39 90 231 30 83 277 70 193 277,Prioritized Problem. FMLA Process Flow Point of Occurrence POO,TMR reviews form T M received.
T M obtains FMLA T M submits form Payroll system,submits by paycheck with. form to TMR by deadline updated by deadline,deadline correct amount. Problem FMLA paperwork is not received from TMR by the payroll deadline. Example Step 2,8 Steps Proceedings, 1 Clarify the Ultimate Goal of your responsibilities work. Step 1 2 Clarify the Standard of your work,3 Clarify the Current Situation of your work. Clarify the problem 4 Visualize the gap between the Current Situation and the. 1 Break down the problem,Step 2 2 Identify the prioritized problem.
Break down the problem 3 Specify the point of occurrence by checking the process through GENCHI. 1 Make a commitment,Step 3 2 Set measurable concrete and. Set a target challenging targets,Step 3 Set a Target. STEP1 STEP2,Prioritized Point of,Problem Occurrence. Step 3 Set a Target,3 Target Setting,Target Eliminate 5 tail light area water leaks on. Camry by 7 29,Example Step 3,3 Target Setting,Target Eliminate 100 late submissions of FMLA.
forms to meet payroll deadline by arch 2009 193,of 660 total gap. Example Step 3,Example through Steps 1 2 3,1 Clarify the Problem. Ultimate Goal No waterleaks in TMMK produced cars, Ideal Situation Standard Zero audit defects from Sealer area. Current Situation 7 waterleaks on 7 28 10,Actual Goal. 2 Break Down the Problem,7 Water leaks,1 on Avalon 6 on Camry Vehicle Type.
1 in Mohican 5 Tail light 1 side Process,Many water leaks in the tail light Prioritized. Go and See Investigation for Point of Occurrence,1 Floor Brush Finish lower seam on end panel. 2 Engine Room Finish Finsh the area just above and below the tail light. 1st Engine Engine,Floor Brush Room,Application Room Brush Application. Finish Hood Finish Rear Finish Finish Finish,Finish Side. Corner Hood Mirror Upper end below tail,tail light.
Plate panel light,Point of Occurrence,3 Target Setting. Target Eliminate 5 tail light area water leaks on Camry by 7 29. 1 Clarify the Problem, Ultimate Goal TMs are compensated for work completed and paid timely and fairly. Standard 100 3300 of TM s paychecks are 100 2640 Gap 20 660. deposited error free 80, Current Situation 80 2640 of TM s paychecks 60 80 100. are deposited error free 40,Current Standard,2 Break Down the Problem. 20 660 3300 manual checks being issued,Group Leader Error Other Salary Continuation.
35 231 660 23 151 660 42 277 660, Time Execution Other STD Not Paid FMLA PTO Not Paid. 61 142 231 39 90 231 30 83 277 70 193 277,Prioritized Problem. FMLA Process Flow Point of Occurrence POO, T M submits TMR reviews Payroll system T M received. T M obtains, form to TMR by form submits updated by paycheck with. deadline by deadline deadline correct amount, Problem FMLA paperwork is not received from TMR by the payroll deadline.
3 Target Setting, Target Eliminate 100 late submissions of FMLA forms to meet payroll deadline by. March 2009 193 of 660 total gap,Example through Steps 1 2 3. Step 1 Proceedings,Clarify the problem, 1 Clarify the Ultimate Goal of your responsibilities work. 2 Clarify the Standard of your work,3 Clarify the Current Situation of your work. 4 Visualize the gap between the Current Situation and the. Step 2 Standard,Break down the problem 1 Break down the problem.
2 Identify the prioritized problem,1 3 Specify, Make the point of occurrence by checking the process through GENCHI. a commitment,2 Set measurable concrete and challenging targets. Set a target,1 Examine the Point of Occurrence and. think of possible causes without prejudice,2 Gather facts through GENCHI GENBUTSU. Analyze the and keep asking Why,Root Cause 3 Specify the root cause.
Step 4 Analyze the Root Cause,Prioritized Problem at the Time for. Point of Occurrence, Possible Possible Possible Possible Think of all meaningful. cause cause cause cause,possible causes,Not a fact Not a fact Not a fact Fact. cause Go and See to confirm,Not a fact Not a fact Fact. Possible Possible Repeat,cause cause,Not a Fact,Root cause.
Step 4 Analyze the Root Cause,Example Bad polishing of painted parts. Standard work being followed,RPMs correct,Correct compound. Polishing standard correct,Environment,Work place temperature correct. Step 4 Analyze the Root Cause, Example Welding robot stops in the middle of its operation. Why A fuse in the robot has blown,Why Circuit overloaded.
Why The bearings have damaged one another and locked up. Why There was insufficient lubrication on the bearings. Why Oil pump on robot is not circulating suffi,Why Pump intake is clogged with metal shavings. Why No filter on pump intake as designed Root Cause. Step 4 Analyze the Root Cause,4 Root Cause Analysis. Waterleaks on the left side tail light,T M leaving gaps in finish. T M not turning spatula into the seam, T M not instructed in proper angle of finish when trained. No specification in STW for proper spatula angle when finishing ROOT CAUSE. Apply the therefore test to check thinking,Example through Step 4.
Step 4 Analyze the Root Cause,4 Root Cause Analysis. FMLA paperwork is not received from TMR by the payroll deadline. Form doesn t pass review,Form was submitted incorrectly. Part D not complete,T M thought HR was to complete. Instructions not clear in Part D,Apply the therefore test to check thinking. Example through Step 4,Step 4 Analyze the Root Cause.
Example Step 4,8 Steps Proceedings,Clarify the problem. 1 Clarify the Ultimate Goal of your responsibilities work. 2 Clarify the Standard of your work, Step 2 3 Clarify the Current Situation of your work. 4 Visualize the gap between the Current Situation and the. Break down the problem Standard,1 Break down the problem. 1 Identify the prioritized problem,a commitment,Step 3 3 Set. 2 Specify the point,measurable of occurrence,concrete by checking.
and challenging targets the process,Set a target through GENCHI GENBUTSU. 8 Step Problem Solving Method Learning Goals Deepen your awareness of the importance of the 8 step process to effective problem solving Apply the process to your own work situation during class discussion Experience how the A 3 tool communicates the process thinking Apply in the work environment that will work both in the field and in the on campus lab 2 8 Step Process

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