Problem Solving Tools
Prepared by Steven Schafer, September 16, 2009
Generic approach to Problem solving
Problem Solving can be broken up into 6 basic steps:
1. Problem Definition
2. Determine Possible Causes
3. Failure Cause Investigation
4. Select and Verify Solution
5. Plan and Implement Permanent Solution
6. Verify Solution is Effective
Prepared by Steven Schafer, September 16, 2009
1. Problem Definition
Before one can start the Problem Solving Process, the
problem needs to fully understood. This description
should include:
– Where the problem occurred
– Under what conditions was the problem observed
– Extent of the problem (100%, one out of 7, etc.)
– Anything else that adds to the knowledge of the
problem.
The problem has been fully defined once you can no longer
come up with additional questions you need answered to
understand the Problem.
Prepared by Steven Schafer, September 16, 2009
2. Determine Possible Causes
This process consists of listing all the possible causes that could contribute to the problem.
Clue generation:
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Cause and Effect Diagram / Fish Bone Diagram / Ishikawa Diagram
Flow Chart / Diagram / Arrow Analysis
Run Chart
Histogram
Pictograph / failure concentration diagram
Control Chart
Brainstorming
Gantt Charts
Rings of Influence
Consensus
5 Why’s / Why-Why diagram
Multi-vari
Component Search
Pair Comparison
Nominal group techniques
Tabular arrangement
Force Field analysis
Affinity diagram
Interrelationship diagraph
Program decision process chart
Matrix
Check list / sheet
Pareto analysis
Ranking
Process Mapping
Scatter Plots
Tree diagrams
Prepared by Steven Schafer, September 16, 2009
3. Failure Cause Investigation
The focus of this process is to determine the true Root Cause.
If the process that creates the problem is complex and has many parameters / factors that can
influence the outcome, then more complex tools , such as, DOE might be needed to arrive at an
understanding of what combined factors are causing the problem.
Some tools that help arrive at the root cause are:
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DOE Tools
Solution Tree / Fault Tree Analysis
Formal experimentation
Study of worker methods
Correlation
Piece-to-Piece variation
Within piece-to-piece analysis
Stream-to-Stream analysis
5 Why’s / Why-why diagram
Run Charts
Histograms
B vs W (BOB vs WOW, Best Of the Best vs Worst Of the Worst)
Autopsies
What can the parts tell us
Prepared by Steven Schafer, September 16, 2009
4. Select and Verify Solution
The focus of this process is to select a solution that will “Kill” the
problem, that is eliminate the possibility of the problem from
occurring in the future.
Verify the measurement system:
– MSA
– Isoplot
– Gage R&R Studies
Some tools to verify solutions are:
– Single Factor Confirmation
– Full Factorial Experiment
– Process capability analysis
Prepared by Steven Schafer, September 16, 2009
5. Plan and Implement Permanent Solution
The focus of this process is to plan and implement the
solution into production.
Things to consider in the planning stage are:
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Error Proofing
Preventative maintenance
PCP
DFMEA / PFMEA
Operator instructions
Visual aids
Design changes
Standardize
Prepared by Steven Schafer, September 16, 2009
6. Verify Solution is Effective
The focus of this process is to ensure that the solution truly
eliminates the reappearance of the problem.
This is accomplished by using tools that collect and
analyze data, such as:
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Check Sheets
Pareto analysis
Control charts
Plant returns
FTQ charts
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking
Note 2: For other column headers see
Figure 2.1 on last slide
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking
Note 2: For other column headers see
Figure 2.1 on last slide
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
Note1: E/F (Expand / Focus our Thinking
Note 2: For other column headers see
Figure 2.1 on last slide
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009
From: The Quality Toolbox, by Nancy R. Tague
Prepared by Steven Schafer, September 16, 2009