IDENTIFICATION OF PROBLEMS

Q: Why We must identify _ problem especially before ( before take decision important or
take action particular )?

Waste of Work:
Waste : anything that is excess beyond the minimum requirements for equipment,
materials, components, work space and time that is absolutely necessary for the added
value process of a product ( Fujio Cho ).

Operator Goods & Materials Machine

•Waiting for •Transportation •Set-up time

Materials •buildup •Machine Trouble
•Keeping an eye on •Inspection •Unproductive
the Machines •Rework treatment
•Producing defective
products
•Looking for work
tools
•Making unnecessary
items

7 Waste ( Waste )
1. Over Production
2. Waiting Time
3. Transportation
4. Processing
5. Goods Inventory Level
6. Unnecessary movement
7. Production Defects
Troubleshooting Steps

Determine the Look for the Examine the

priority of the causes of the most influential
problem problem causes

Check the Arrange

Implement
results of the Corrective
corrective steps
repair Steps

Prevent
Solve the next
recurrence of
problem
the problem

Problem Identification Tool

1. 7 Tools
a. Check sheets
Description - Purpose : A prepared form _ For collect , confirm and analyze data.
Used if : Collecting data in the form of frequency or pattern incidents , problems ,
defects and others. Data got collected and observed in a manner repeated by the
same person or at the same location .
b. Histogram
Something graphic depicting _ deployment amount of data to in a number of
shape classification _ four rectangle long such so that observed data
characteristics Can seen more clear .
c. Pareto Charts
A diagram showing a number of events sequentially from the largest to the
smallest class with their cumulative total
d. Cause and Effect Diagrams
 Diagram to analyze the cause of a problem
 Consists of 5 causative factors: human, machine, method , material, and
environment
 Provides information about possible causes
  Filling in the fishbone is assisted by brainstorming techniques and the
Technical Nominal Group (NGT).
 Procedure :
 Define tree problem ( result main ) and write in section middle
adjacent right .
 Awaken a number of category because main . Use category methods ,
equipment , people, materials, measurements and the environment .
 Draw a horizontal line from consequence main , then make the branch
connecting the line from consequence main to reason main _
 For every because main , ask “ Why because main the Can happened
?”. Note the answers you get ( say as sub- causes ) and describe them
as a branch of because main .
 Repeat step 4 for each sub- cause and create child the branches .
e. Stratification: grouping/ classifying/ stratifying data based on certain factors for
more detailed analysis. Example : Factor Stratification general . Grouping data based
on ….
 Who: Department, individual, type of customer
 What: Complaint type, defect category, reason for calling
 When: monthly, quarterly, day, time
 Where : section, city, specific location of the product (upper right corner,
on / off button , etc. )
f. Scatters Charts
 A diagram depicting the correlation/between two variables and their
levels
 2 correlations, namely there is and there is no correlation, the level is
strong or weak
 Provides information about the correlation/relationship between 2
variables. If strong is the dominant cause
g. control Charts
Tool to detect whether a process is still in its original state or has undergone a
change in properties. Maps are used to analyze the variation of a process by
mapping historical process data (variables or attributes).
 Set limits on decision-making actions in statistical quality control.
Used when:
 Ensure that the process is stable.
 Analyze patterns of process variations due to special causes or common
causes.
 Will implement process quality improvement.
 Monitor and control running processes.
Control Map consists of: 1. Attribute Control Map
2. Variable Control Map.
2. 5W 1H
 what : what needs to be fixed
 why : why improvement is needed
 who : who should make repairs
 where : where the fix needs to be done
 when : when the repair needs to be done
 how : how the repair is carried out
3. Work Map Map
4. NBM, QEC, RULA, REBA, OWAS

8 Steps for using 7 tools

1. If there are many problems, choose and work on one problem that is most important
to solve first. Tools used :
- check sheets
- histograms
- pareto charts
- control map
2. Find the cause of the problem by doing brain storming . Tools used :
- Cause-Effect Diagram (describe the problem on the right and the alleged cause on
the left in a structured manner)

3. Check, whether the causes described above are proven empirically after first filtering
the quantitative causes and effects. Tools used
 - Scatter Diagrams
4. Find the most dominant cause. Tools used :
- Check sheets
- histogram
- Pareto Charts
- control map
5. Plan problem solving using the 5W & 1H formula
6. Carry out consistently and check the results of repairs, then compare before and
after repairs. Tools used :
-Check _ sheets
- Histograms
- Pareto charts
7. Prevent the problem from recurring so that the same problem does not occur again
by:
a. Set new standards
b. If necessary, change the old standards
8. Return to the original problem (whether the problem that has been fixed has shifted
/ not yet) if it has shifted continue to the next problem, if not / is still dominant
repeat the solution method by setting a new target (new improvement target)