Introduction to

Unified Problem Solving

(UPS)

Global FI Pillar
Introduction Content

• UPS workshop objectives

• What is UPS and Why is UPS important
• When to use UPS
• Resources
• Summary
• Video (Mechelen UPS)
• Business Link: Teams and whs agenda
Objectives

By the end of this session, you will be able to:

• Know what the UPS tool is
• Identify situations where UPS applies
• Learn about an example of using UPS
• Know where to find more resources
• Learn by doing
What is UPS?

• Unified Problem Solving

• A method used to solve a problem after daily management
tools have been ineffective
• Used to find the root cause of a problem after the system has
been verified to be within standard
Why is UPS important?

How does it help the business?

• UPS is a repeatable methodology that drills down to

the root causes of chronic problems.
• UPS identifies multiple root causes and provides
countermeasures and sustainable solutions.
• UPS allows modification of existing standards or
creation of new standards to countermeasure an issue.
 DDS Troubleshooting Guide

When to use UPS?

Execute current Systems and work to current Standards
(CL, CIL, PM, etc.)

Gap in plan
Is it a gap in Breakdown
execution Use B/D
plan execution or a new
Elimination DMS
problem?

New results gap

Equip. Owner define IMMEDIATE ACTIONS to close
the safety, quality or process problem based on current RESTORE TO EXISTING STANDARD

• Use UPS for problems that skill based on simple 4 M analysis

1. Execute CILs
2. Restore equipment back to Midrange (CL)
3. Replace raw material not in spec
CONDITIONS IMMEDIATELY (ON SHIFT)

cannot be solved by existing 4. Fix the utilities problems

Is it a barrier to
Yes 1. Optimize resources and plan

daily management tools and

immediate results ? 2. STOP AND DO THE WORK
No
Is it a barrier to
Yes
mid-term results ?
Plan and Scheduling - weekly

are verified to be at the Line Team Morning

No

standard.
Meeting Do I have a No Collect data for
chronic Loss? Monthly review
Yes
DEEP CHECK ALL 4Ms IN STANDARD CONDITIONS
Equipment Owner to confirm at base condition on each M supported
VERIFY ALL STANDARD CONDITIONS
by Tech. expert Review all documentation – , MES system, MQM,
WPA, Trouble Shooting guides. AFTER PRODUCTION MEETING
Output – Immediate Cause identified

• Click here to see the DDS Is problem solved ?

No
Yes

IDENTIFY TRUE ROOT CAUSE

Troubleshooting Guide. Line Leads

Unified Problem Solving

(Tracked in the Production Meeting)

June 09
System Owner Leads

Determine which DMS /

Process Forms Used Work process failed to maintain
0 Ensure System at
Large Vague Problem - DDS Trouble Shooting Base condition and Why
Standard guide
Method Loss - OPM, Standards, WPI
1 Problem
SEE
Human Loss - OPM, Skills
The Problem
Investigation - 6W-2H Problem Analysis
ON THE FLOOR

System Owner updates standards,

Cause and Effect - Cause-Effect Diagram (Fishbone)
2 Cause Identification Analysis - Cause-Effect Worksheet

True
- Cause-Effect Summary
Deploy to Organisation
Cause
WHY
WHY
Root Cause Investigation WHY - Why it Happened/Passed?
3 WHY
ON -PM Analysis
WHY
O if problem not solved
UPDATE STANDARDS
Implement, OFF
4 O & DEPLOY ASAP
Evaluate Counter Measure
Problem - Problem Solving Summary
Standardize

5 Sustain Results - C-E Summary and Countermeasures

- QX Matrix
- QM Matrix
UPS vs WPI

• WPI is used for any work process that involves

humans.
• UPS primarily helpful for equipment related
problems

Although the above statements are generally

true, both tools may be applied in either
situation.
UPS Processes

1. Understand the Situation

2. Root Cause Investigation
3. Implement, Evaluate
Countermeasure
4. Sustain Results
5. Standardize and Reapply
Can I run a UPS session?

• The only way to get trained and qualified

to execute the UPS process is through
participating in a standard UPS
workshop.
 How to access UPS Resources
More information on UPS workshops and the FI pillar can be found
here: FI Sharepoint

Interested in participating in a UPS workshop?

Contact your FI GBU leader, Continuous Improvement leader, or Site

Pillar Leader for more information. All sessions must be led by a
qualified facilitator. Link to FI Team Members
Summary
• UPS exists to find solutions in situations where processes are within
standard and Daily Management systems are no longer effective
• By creating a focused problem statement, UPS is able to identify
multiple probable causes
• Why-Why analysis asks why a root cause occurred and identifies
countermeasures
• Sustained process performance is expected by continual observation
at the point of cause
Mechelen, living UPS

UPS Video
UPS Teams, (example)
UPS Agenda (example)