I've got a problem
Name at least two of the Four Steps of Problem Solving
Define
Analyze
Countermeasure
Sustain
What does SIPOC stand for?
Supplier, Inputs, Process, Output, Customer
Where do you go to validate information or cause?
The Genba!
What is another term for mistake proofing?
Poka yoke
Name at least one tool to use to Standardize and Sustain
Standard Work
Leader Standard Work
Daily Management
Genba
Name the tool used to show steps in a process
Process Flow chart
Problem solving is a ____, it is NOT just a set of tools
Mindset
Name at least two root cause analysis tools
Root Cause Tree
5 Whys
Fishbone Diagram
FMEA
DMAIC
What is a Temporary countermeasure?
Iterative measure intended to experiment, contain or adjust the problem immediately. May buy you time to investigate root causes.
Why is it important to Standardize and Sustain?
Sustain gains won /Stability (avoid regression)
Create consistency for new employee or cross training
Sets up process for next step change (new stepping off point to continue improvements)
What are the three areas of the Problem Solving Tree?
Problem
Reasons
Level 1 (L1) Pareto describes the ____?
Where
What are 3 types of Root Causes?
Process does not exist
Process not capable
Process not followed
What is a Permanent Countermeasure?
A preventive action to address the root cause and close the gap. Typically built into the process and standardized.
Name at least one outcome of Standardizing and Sustaining
Sustainment Plan
New or revised Standard Work
Celebration!
What does TAGS stand for?
Trend
Actual
Gap
Standard
Level 2 (L2) Pareto describes the ____?
Why
Problem solving is a _____, not a tool
Mindset
Name at least one activity you can do with a team to develop ideas for countermeasure?
Brainstorm
Prioritize (impact and effort matrix)
Trystorming
What is the concept of Catchball?
Vetting your action plans with those who will implement them, thus reducing the risk of action plan failure
Define: "What is a problem"
A gap between Current and Standard (Target)
Define Genba
The place where the work is done and value is created. “Going to Genba” is involved in every step of the Problem Solving process.
What is the Pareto Principle
(explain in your own words)
80% of consequences (problems) come from 20% of causes
What is Trystorming?
Process of moving quickly to test your potential countermeasure (hypothesis).
Done quickly, hands on, in order to test assumptions and learn what will work to
solve the problem, reduce risk, etc.
What are the elements of a good sustainment plan?
Who, What, When, How & So What
Who will check?, what will be checked?, when?, how often (how long)?, how will we know it's working (what is standard to tell if it's working)?