CHAPTER 3 – BDA 10602

3.1 CONCEPT OF CREATIVE PROBLEM SOLVING

3.2 SIX STAGES IN CREATIVE PROBLEM SOLVING

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 3.1 Concept of Creative
Problem Solving

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3.1 CONCEPT OF CREATIVE PROBLEM
SOLVING

Creative Problem Solving:

An Overview

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 What is Creative Problem Solving
(CPS)?

CPS - a proven method for approaching a problem or a

challenge in an imaginative and innovative way.

CPS - is the mental process of searching for an original

and previously unknown solution to a problem. To qualify,
the solution must be novel and reached independently.

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 What is Creative Problem Solving
(CPS)?

• It is a process that helps you redefine the problems and

opportunities you face, come up with new, innovative
responses and solutions, and then take action.

• The tools and techniques used make the process fun,

engaging, and collaborative.

• CPS not only helps you create better solutions, it creates a

positive experience that helps speed the adoption of new
ideas.

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3.2 Six Stages in Creative
Problem Solving

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 …summary

Explore 1. Identify the Goal, Wish or

The Challenge (Objective Finding)
Challenge 2. Gather Data (Fact Finding)
3. Clarify the Problem (Problem Finding)
Generate 4. Generate Ideas (Idea Finding)
Ideas
Prepare 5. Select & Strengthen Solutions
for Action (Solution Finding)
6. Plan for Action (Acceptance Finding)
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 • Identify the Goal, Wish or Challenge
• Gather Data
• Clarify the Problem

• Generate Ideas (Diverging)

• Select & Strengthen Solutions (Converging)

• Plan for Action

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 1 2 3 4 5 6

Explore the Challenge

Identify the Goal, Wish or Challenge

• State a variety of goals, wishes or challenges.
• Choose a goal, wish or challenge where you have
ownership, motivation and a need for imagination

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 1 2 3 4 5 6

Explore the Challenge

Gather Data
• Explore all data around the goal, wish or challenge.
• Identify all the relevant data
• Use Journalist’s questions 5Ws & 2Hs (if related)
•Who…? What…? When…? Where…? Why…? How…?
How much…?

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 1 2 3 4 5 6

Explore the Challenge

Clarify the Problem

• State the problem in as many ways as possible.
• Choose a problem statement to work on.

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 1 2 3 4 5 6

Generate Ideas

Ideas Finding
• Think up a wide variety of ideas to solve the problem
(Diverging).

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 1 2 3 4 5 6

Prepare for Action

Select & Strengthen Solutions
• Evaluate and refine the ideas you selected.
• Select the most promising solution(s) (Converging).
• Many similar ideas – Restate
• One idea
• Diverse Ideas – Evaluation Matrix
• Many ideas of equal worth – Card Sort

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 1 2 3 4 5 6

Prepare for Action

Plan for Action
• List a series of possible actions for implementation
• Form a specific plan for action:
• Select key actions to implement.
• Create a plan that details who does what, by when,
reporting completion to whom.

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 1 2 3 4 5 6

Prepare for Action

Goals Action By Whom By When Reporting completion

to whom
Immediate

Short

Medium

Long Term

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 1 2 3 4 5 6

Explore the Challenge Generate Prepare for

Ideas Action

DIVERGING & CONVERGING

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Example of case study using CPS

• Case: Increment of rejected helmet in production

line.

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 Explore the Challenge

1
• Identify the Goal, Wish or Challenge

• To decrease the rejected helmet

• To figure out highest defect factor
• To find out countermeasure step to reduce defects

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 Explore the Challenge

2
• Gathering Data

• Study focus derived using 5W 2H

• Who – machine, operator and QC inspector
• What – working procedure, working method, machine -
operation
• When – operating hours
• Where – production line
• Why – to be identified
• How – study types of defects and its statistics
• How much – to be measured

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 Explore the Challenge

2 •Gathering Data

Measurement Method Machine

- long working hours - Unproper clean room - Clogged sprayer

entrance procedure - Dirty oven
- High output requirement - Spray method not - not calibrated oven
follow procedure

Helmet
- Not follow sop
reject
- Slow curing process - Rushing for output

- High viscosity, less - Not critical - High humidity on rainy

viscosity season
- weak QC/ less concern
- Dusty environment
Material Manpower Environment
21
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 Explore the Challenge
2
• Gathering Data
Cause Cause details
Category
Measurement - Long working hours
- Two shift implementation
- High output requirements
Method - Clean room entrance
improper
- Not follow spray procedure
Machine - Clogged sprayer
- Dirty oven
- Oven not calibrated
Material - Slow curing
- High/low viscosity
Manpower - Not follow SOP
- Rush for output
- Not critical
- Weak QC/ less concern
Environment - High humidity especially on
rainy season
- Dusty environment
Data details
- Each operator needs to work for 12hours per day
- Factory chasing for 1000 unit output per day
- Thru survey, 50% operator not change their shoes during clean
room entrance
- 30% operators not follow spraying procedure by skip 50%
spray flow
- Spray gun become clogged due to longer operating hours
- 5S oven scheduled not followed
- 4 out of 10 oven exceed calibration schedule for 2months
- Operator skip mixing time for 15minutes
- 30 out of 96 spray operator had found to skip the process by
step or by time
- Humidity increase for 50% during rainy days
- Particle contents in air increase 20% during normal condition
and 40% on hot days
 Explore the Challenge

3
• Clarify the Problem

• Through data gathering, the main problem that had cause

helmet defects is spraying process station which lead by
improper procedure and facilities

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 Generate Ideas
4 • Diverging

Cause Cause details Countermeasure ideas

Category
Measurement - Long working hours - Separate into three shift
- High output requirements

Method - Clean room entrance - Re-training and stress the importance of the procedure
improper
- Not follow spray procedure
Machine - Clogged sprayer - Don’t use same sprayer continuously
- Dirty oven - Extra sprayer have to be purchase to implement one shift
- Oven not calibrated one sprayer, so each shift will used well maintained sprayer
- Calibration section have to be developed to
Material - Slow curing - Re-training for mixing process
- High/low viscosity

Manpower - Not follow sop Re-training

- Rush for output
- Not critical
- Weak QC/ less concern
Environment - High humidity especially on - Heater system have to be enhanced in order to improve
rainy season humidity
- Dusty environment - Filtration system have to be improved
 Prepare for Action

5 • Select & Strengthen Solutions

• (Converging)
Criteria (1-5 rating)
Cause
Countermeasure Ideas
Category Criteria 1 Criteria 2 Criteria 3 Total
(Cost) (Manpower) (Effectiveness) Marks
Measurement - Separate into three shift
3 3 5 11
Method - Re-training and stress the importance of
the procedure 4 4 4 12
Machine - Don’t use same sprayer continuously
- Extra sprayer have to be purchase to
implement one shift one sprayer, so each
shift will used well maintained sprayer
2 3 5 10
- Calibration section have to be developed to

Material - Re-training for mixing process

4 4 4 12
Manpower - Re-training manpower
5 5 5 15
Environment - Heater system have to be enhanced in
order to improve humidity
- Filtration system have to be improved 1 3 5 9
 Prepare for Action

6 • Plan for action

Reporting
Criterion
Goals Action By Whom By When completion
Marks
to whom
- Re-training and stress the
importance of the procedure 12
Before end of Head of

Immediate
- Re-training for mixing process
12 Training unit this week manufacturing

Re-training man power

15
Short - Separate into three shift
11 HR 1 March MD

Medium - Don’t use same sprayer continuously

- Extra sprayer have to be purchase to 10 Production B4 3rd quarter Head of
implement one shift one sprayer, so Facilities 2018 manufacturing
each shift will used well maintained Management
sprayer Section
-calibration section have to be
developed to
Long Term -heater system have to be enhanced
in order to improve humidity 9 Building
Facilities
B4 2nd
quarter 2019
Head of
manufacturing
-filtration system have to be improved Management
Section