F&M Department

TRAINING OUTLINE :

PART – 1 :

I. Continuous Improvement

II. Typical Reaction to the Problem

III. Definition of a Problem

IV. PDCA + Grasp The Situation

PART II :

VI. 8-Step Lean Problem Solving Process

PART – I
Continuous Improvement
 Continuous Improvement Mindset

Continuous Improvement or also known as KAIZEN, is a long-term

approach to work that systematically seek to achieve small, incremental
changes in process in order to improve efficiency and quality.

illustration:
Continuous Improvement Mindset
Continuous Improvement Mindset
Continuous Improvement Mindset
Continuous Improvement Mindset
Typical Reaction to a
Problem
Traditional common response

Work around the problem to stop it

Doing what it takes to address the issue

Problems are not talked about – they are hidden until they
become worst

When we see problem, we brainstorm for solution and fixes

We ask WHO? And start blaming people

“ Leading to more unresolved and even bigger problems “

LEAN way....

What is LEAN?

LEAN is a socio-technical approach to work and management

A different paradigm of management

It is about creating the most value for the customer while

minimizing the producers resources ,time , energy and
effort.
A Lean Organization
In summary.....

LEAN

It is about understanding what really is going on in the “ GEMBA “ ( The place

where value is created )

Improving the process by which products and services are created and dilevered,

And empowering people through problem solving and coaching.

Improvement Activity = Normal Daily Management

Traditional response LEAN Common
to a Problem Response

Work around a problem to Ask WHY the problem

stop it occurred and what caused it.

Doing what it takes to Problems are opportunities

address the issue for improvement and must
therefore be seen and
Problems are not talked eliminated
about – they are hidden
until they become worst When we see a problem we
brain storm for the cause
When we see the problem, after understanding what it
we brainstorm for is.
solutions and fixes

We ask WHO? And start We go SEE ask WHY? And

blaming RESPECT people.
Definition of a Problem
What is a PROBLEM?

Is a deviation from a standard or a target.

Exist when there is a gap between the

current performance
of a process, products or service, and the
desired performance
 What is a problem?

GAP
What should
be happening?

What is actually happening?

 Types of Problems;

Type 1 – A standard is NOT achieved

Type 2 – A standard achieved, but a higher

standard is now required

Type 3 – Performance to a standard varies

( not consistently achieved )
PDCA + Grasp the
Situation
PDCA + Grasp the situation
 PDCA + Grasp the situation

Grasp the Situation: Is asking question such as;

What is supposed to happen?

What is actually Happening?

WSH

Problem

WAH
PDCA + Grasp the situation
 PDCA + Grasp the situation

It Easier to set a target

condition

Target condition

Current condition

...than to roll up our sleeves and do

the hard work required to achieve
it.
END OF PART – I