Many manufacturing and production processes suffer from undesirable variations, rework, and rejects. Cause-and-Effect Diagram Data Collection & Analysis 8. Lean Manufacturing Problem Solving Methods ... despite several years of our teaching him he has missed a fundamental point about the role of PDCA versus specific tools. It was enlightening because it reminded me how learning takes place over time, with repeated coaching, as the student learns and questions. Barrier Analysis 11. Because it's simple, you can adapt it quickly and apply it to almost any problem. It can also help you get buy in from team members for the solution chosen - after all, they have helped create that solution. Human Performance/ Human Factors Root Cause Analysis Techniques. Many other processes like automobile axle/wheel alignment, suffer from unacceptable first time capability. Six Sigma, Lean Manufacturing, Certified Quality Managers. SPC Chart 7. If you own a business, or if you are a manager within an organization, solving problems is one of your key duties. Solving problems is at the core of running a business and these problem solving tools will help you to take a structured and methodical approach. ii ACKNOWLEDGEMENTS I wish to firstly thank the help and guidance provided by my supervisor, Dr Ahmad Suhaimi Baharuddin. 1.2 The New Approach to Problem Solving Often manufacturing specialists experience difficulties resolving critical production and manufacturing problems. Defining the problem 2. It is important to prevent these defective parts from reaching the customer. Brainstorming 10. A common mistake in problem solving is that alternatives are evaluated as they are proposed, so the first acceptable solution is chosen, even if it’s not the best fit. Check sheets Data Collection 2. Brainstorming and team problem-solving techniques are both useful tools in this stage of problem solving. Mind Tools add, “The 5 Whys strategy is an easy and often-effective tool for uncovering the root of a problem. Implementing solutions The Problem Solving Possibilities Diagram can be used as a guideline to … His guidance throughout the … Problem solving tools are determined by the requirements of the problem and the amount of time to solve the problem. The 5 Whys 9. While the problem solving team is trying to find the root cause of the problem and implement corrective actions, there will be some defective products produced by manufacturing. Evaluating and selecting alternatives 4. 8. In fact, it may be the activity which takes up most of your time each day. Histogram 5. guides the team through the 8 disciplines using the appropriate quality tools at each step. ... Management Problem-Solving Tools 1. It's a good tool to start your problem solving process but often requires additional follow-on methods. There are four basic steps in problem solving regardless of size or complexity: 1. ADOPTION OF PROBLEM SOLVING TOOLS IN MANUFACTURING SECTOR OF MALAYSIA SMALL AND MEDIUM ENTERPRISES by LOW RONG QUAN Thesis submitted in fulfillment of the requirements for the degree of Masters in Science NOVEMBER 2015 . Generating alternatives 3. 2 Techniques / Tools Brainstorming SWOT 5 Why’s Drill Down Flowcharting Analytical Problem Solving Brainstorming Used to develop a large number of creative solutions to a problem. Many alternative solutions to the problem should be generated before final evaluation. Pareto Analysis 3. Flow Chart 4. Scatter Diagram 6.