Problem Solving Form (DMAIC Lite) DEFINE Plant Equipment Date Problem Potential Team Members Initiator Tracking Number Describe Problem Start Date: Completion Date: What: Initial Data When: Where: Who: Problem Statement MEASURE In this space insert charts and/or drawings to stratify the problem to the lowest level. Use additional forms if necessary. ANALYSIS 4-M Analysis [ Brainstorm potential causes of the incident based on data, observation, and experience. ] huMAN MACHINE Problem Statement METHOD MATERIAL ANALYSIS (Continued) Why-Why Analysis [ Evaluate "The Critical Few" to identify Root Cause(s). ] WHY? WHY? WHY? se ne par ce ate ss ar she y e ti f WHY? Co nt in ue on Problem Statement POTENTIAL ROOT CAUSES Rank Potential Root Cause Rank Potential Root Cause IMPROVE Top Root Cause(s) Countermeasure Countermeasure Ladder Level Responsible Target Completion Date Actual Completion Date CONTROL CHECK RESULTS Countermeasure Time Period Tracked REPLICATE AND STANDARDIZE Results Item Std Work/SOP Update Educated? Update PM? Replication Required Yes No Yes No Yes No Yes No Yes No Yes No Description Target Date Responsible Completion Date Problem Solving Form (DMAIC Lite) DEFINE Plant Equipment Date Problem Potential Home Car 1/10/2021 Wreck Team Members Describe Problem Initial Data Flat Tire What: Flat Tire Right front When: 1/10/2021 Where: Driveway Who: Problem Statement Me Initiator Me Tracking Number 1/10/2021 Completion Date: 1/10/2021 Me I got ready to run errands and saw my right front tire was flat MEASURE In this space insert charts and/or drawings to stratify the problem to the lowest level. Use additional forms if necessary. Nails found in this area ANALYSIS 4-M Analysis [ Brainstorm potential causes of the incident based on data, observation, and experience. ] huMAN New Hires on Job MACHINE No tools to pick up nails Flat scraper used to pull shingles off - Nails came out at same time Problem Statement Flat Right Front Tire Training procedures non existent Rubber Tire Steel Nails Nails in driveway and yard METHOD MATERIAL 1 Start Date: ANALYSIS (Continued) Why-Why Analysis [ Evaluate "The Critical Few" to identify Root Cause(s). ] WHY? WHY? WHY? WHY? Roofing Nail in Tire Nail in Driveway WHY? Contractor did not clean up nails Tire Lost Air No Procedures to address lost nails No Tools to help find lost nails Problem Statement No catch mechanism to catch wayward nails Right Front Tire Flat POTENTIAL ROOT CAUSES Rank Potential Root Cause 1 No procedures to catch lost nails 2 No tools to help find lost nails 3 No catch mechanism to catch wayward nails Rank Potential Root Cause IMPROVE Top Root Cause(s) Countermeasure Countermeasure Ladder Level Responsible Target Completion Date Actual Completion Date No procedures to catch lost nails Develop procedure and educational plan for associates to find nails 1 Contractor 1/15/2021 1/15/2021 No tools to help find lost nails Purchase and begin using magnet to pick up nails 5 Contractor 1/15/2021 1/15/2021 No catch mechanism to catch wayward nails Design and implement catch mechanism to eliminate nails from reaching the ground 6 Contractor 1/15/2021 1/15/2021 CONTROL CHECK RESULTS REPLICATE AND STANDARDIZE Countermeasure Time Period Tracked Results Procedure to find nails 3 months No flat tires from customers Use magnet to pick up nails 3 months Catch mechanism 3 months No flat tires from customers No nails found on driveway No flat tires from customers No nails found on driveway Item Std Work/SOP Update Educated? Update PM? Replication Required Yes No Yes No Yes No Yes No Yes No Yes No Description Updated procedures Educated Team PM Procedures updated Replicated to crews Target Date 1/15/2021 1/21/2021 1/15/2021 1/15/2021 Responsible Contractor Contractor Contractor Contractor Completion Date 1/25/2021 1/25/2021 1/15/2021 1/15/2021
