Problem Solving

Overview

Solving Efeso © 1999 rel. 7 2010/02/18

 Problem Solving is the process that eradicates problems

A problem has to be understood, studied and the countermeasures

implemented in such a way that
 we are able to achieve the World Class level, setting a vision
 adopting a practical and systematic approach… without forgetting the
difference between fixing and solving
 a few simple guidelines are followed
 for each problem a focused improvement method is given
 based on a sequence of simple steps

1.0 Problem Solving Overview Solving Efeso © 1999 -2-

 The World Class level to be achieved

To be World Class…

MORE than 70% of the problems occurring

have to be eradicated

World Class

The typical starting point…

LESS than 10% of the problems that occur

are eradicated

1.0 Problem Solving Overview Solving Efeso © 1999 -3-

 Setting the Vision...

100%
Not Cost
90% 20% Effective
80% Root Cause
10% Unknown
70%
Eradicated
60%
90%
50%

40%
70%
30%

20%

10%
10%
0%
Start World Class

… through an Implementation Approach

1.0 Problem Solving Overview Solving Efeso © 1999 -4-
 … without forgetting the difference between fixing and solving

There is a big difference between

 PROBLEM SOLVING

And

 PROBLEM FIXING

FIXING A PROBLEM eliminates the symptoms,

not necessarily the root causes

1.0 Problem Solving Overview Solving Efeso © 1999 -5-

 Z

A Simple Example

Logistics example

Problem Fixing Problem Solving

Problem Problem
e.g. tool changer e.g. tool changer
fault fault

… …

The Sensor The Sensor

Lens is dirty Lens is dirty

There is not a Sensor Lens is difficult

Cleaning Schedule to access
Solution Solution(s)

Clean Introduce a Modify Guard so it is

the Lens Cleaning Schedule easy to get to Lens

1.0 Problem Solving Overview Solving Efeso © 1999 -6-

 Exercise

PROBLEM FIXING versus PROBLEM SOLVING

Can you find similar examples in your areas?

1.0 Problem Solving Overview Solving Efeso © 1999 -7-

 Following some simple guidelines

 Restore before improving

 Apply the 5G Principles

– to factories
– to offices

 Implement the PDCA cycle

1.0 Problem Solving Overview Solving Efeso © 1999 -8-

 Giving focused improvement method to each problem

We have to apply loss-focused improvement methods

 machine… material… man losses
 achieving significant results… quickly
 holding gains

1.0 Problem Solving Overview Solving Efeso © 1999 -9-

 Machine…

 Breakdown reduction
 Set-up reduction
 Speed losses reduction
 Short Stops reduction
 Defects reduction
 “Lack of Material” elimination

1.0 Problem Solving Overview Solving Efeso © 1999 - 10 -

 … Material…

 Defects reduction
 Scrap Reduction
 Overusage reduction

1.0 Problem Solving Overview Solving Efeso © 1999 - 11 -

 … Man losses

 Cycle time standardisation

 Non-value added activity reduction
 Cycle time reduction
 Low-cost automation
 Team organisation

1.0 Problem Solving Overview Solving Efeso © 1999 - 12 -

 Achieving significant results… quickly
Set-up example
Problem Solving Application
Approaches

Time/Event (index)

140
130
120
Variability caused by little problems
and lack of standard
100 Optimised method,
elimination of adjustments,
quick release devices
80

60 70
100 From the best situation, it
40 is easy to identify further
opportunities 60
20 40

0
Start Average Start Variability First Standard Final Standard

1/2 months
1.0 Problem Solving Overview Solving Efeso © 1999 - 13 -
 Holding gains

Standardisation

Index
What to do:
120  Define preventive maintenance activities
and standards
100  Define new operation and control standards
100
 Train people on new standards
 Define a validation system
80
70

60
50

40

20

0
Start of project End of project Six months later…

1.0 Problem Solving Overview Solving Efeso © 1999 - 14 -

 ALC OHP

The Steps for Problem Solving

77
P D
2. Do Standardise
Standardise
1. Plan

66 A C Follow-up
Follow-up the
the results
results
4. (re)Act 3. Check

55 Carry
Carry out
out actions
actions

44 Planning
Planning of
of countermeasures
countermeasures

33 Root
Root cause
cause analysis
analysis

22 Identification
Identification of
of failure
failure modes
modes

11 Problem
Problem Definition
Definition

1.0 Problem Solving Overview Solving Efeso © 1999 - 15 -