PROBLEM SOLVING & ANALYSIS TOOLS

They are tools required to facilitate the process of problem solving, including root cause analysis and corrective action.

IS – IS NOT

“IS – IS NOT” is a problem solving tool that explain the rational process for finding the possible root cause of the problem. This technique also helps user to avoid jumping to a false cause. At the end of the IS – IS NOT exercise user gets a confirmed true cause which helps to establish a plan to fix the problem and prevent it to recur.

Please click here to download the full technical document.

Please click here to download the template of IS – IS NOT.

FMEA

FMEA(Failure Modes and Effects Analysis) is an analysis tool that makes sure that all the potential problems related to product and process are predicted and addressed throughout the product and process development process

Please click here to download the full technical document.

Please click here to download the template of FMEA.

CORRELATION

A correlation is a statistical technique, degree and an index of the relationship strength  between any two or more quantities (variables) in which they vary together over a period and it shows whether and how strongly pairs of variables are related. Possible correlations range from +1 to -1.

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5 WHYS

The 5 Why’s is a simple problem-solving technique that helps you to get to the root of a problem quickly. The technique was originally developed by Sakichi Toyoda, a Japanese inventor and industrialist. The 5 Why’s was used within the Toyota Motor Corporation during the evolution of its manufacturing methodologies and became very popular in the 1970s by the Toyota Production System, and is now used within Kaizen, Lean Manufacturing, and Six Sigma.

Please click here to download the full technical document.

Please click here to download the template of 5 whys.

BRAINSTORMING

Brainstorming is a simple technique for gathering the ideas for developing creative solutions to problems. Brainstorming helps you to have diverse experience of all team members into play during problem solving and/or solution development. This increases the confidence and self satisfaction to all team members and a feeling of ownership of the problem which will also help to find better solutions to the problems you face.

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AFFINITY DIAGRAM

The affinity diagram, also known as the KJ method was developed by Dr. Kawakita Jiro. This diagram gathers together items, needs or features of similar types. It is applied in conjunction with cause-effect diagram for quality design and quality improvement processes.

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TOLERANCE ANALYSIS

Tolerance Analysis is commonly associated as an engineering tool to estimatecumulated variation of multiple component of a mechanical stack-ups and reflecting variation of total system. In general, tolerance analysis can be applied practically anywhere where process stages are happenings equentially with certain variation.

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Please click here for the scenario and here for the template of it.

PDCA

PDCA known as Deming Cycle or Deming Wheel, PDCA is a tool for continuous improvement of processes and products. Deming always referred to it as the “Shewhart cycle”, PDSA (Plan-Do-Study Act). Deming modified it to PDCA because he felt that “check” emphasized inspection over analysis. Current Toyota Production System / Lean manufacturing uses OPDCA where “O” is taken for observation.

Please click here to download the full technical document.

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