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How can you develop problem-solving skills in manufacturing?

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Problem-solving skills are essential for any manufacturing engineer or technician, as they face various challenges and issues in designing, producing, testing, and improving products and processes. However, developing these skills is not always easy, as it requires a combination of knowledge, creativity, logic, and communication. In this article, we will explore some tips and strategies to help you enhance your problem-solving skills in manufacturing.

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Dr. Rajdeep Deb

MAANG Mentor | Technology Integrator | Skill Development | MarCom Specialist
Ványolos-Szigeti Viola

Customer Quality Engineer at Payer Industries Hungary Kft.
Prof.(Dr.)Shailesh Tripathi

Professor and Academic Leader at Sri Balaji University, Pune | MBA, PhD

1 Identify the problem

The first step in any problem-solving process is to clearly define the problem you are trying to solve. This may seem obvious, but sometimes problems are vague, complex, or hidden by symptoms. To identify the problem, you need to gather relevant information, ask questions, and analyze the situation. You can use tools such as the 5 Whys, the Fishbone Diagram, or the Pareto Chart to help you find the root cause and the scope of the problem.

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Dr. Rajdeep Deb

MAANG Mentor | Technology Integrator | Skill Development | MarCom Specialist
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For any problem-solving process identifying the underlying cause of a problem is often considered the initial and crucial step to start with. In addition to the technique mentioned one can also try Root Cause Analysis (RCA), to trace issues back to their origins.

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Ványolos-Szigeti Viola

Customer Quality Engineer at Payer Industries Hungary Kft.
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To identify the problems, not just the relevant informations needs to be gathered, but all what you have, to be able to start the root cause analysis. If you know all the information, it will help you to create the root cause analysis.

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Prof.(Dr.)Shailesh Tripathi

Professor and Academic Leader at Sri Balaji University, Pune | MBA, PhD
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1. Discuss with people who directly work or operate on the unit. 2. Ask every stakeholder to elaborate the real problem. 3. Problem clarity pushes us closer to the solution. 4. Bigger manufacturing problems are cause of small activity gap or simple consistent issues not resolved. 5. Do not work in denial mode. Anyone can faultier, anything can malfunction.

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Fathur Rahman
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In material fabrication or manufactur, to solve the problem, you must read more and more reference from other journal to design the solution. To identify the problem, you need to gather relevant information, and on you need partner to discuss about it . . .

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Gilberto Alvarado Gonzalez

Socio propietario Centro Cultural Japon Mexico Kakehashi
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El definir la profundidad de la responsabilidad de las actividades a realizar, es el primer paso para determinar, que tipo de análisis se requiere Es considerar a los expertos de cada nivel para el análisis de los problemas o determinar las causas reales Los expertos en técnicas de análisis deben ser más un soporte o guía para enfocar el análisis o la identificación de causas

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2 Generate possible solutions

Once you have identified the problem, you need to brainstorm and evaluate possible solutions. You can use techniques such as mind mapping, SCAMPER, or TRIZ to generate ideas and stimulate your creativity. You should also consider the feasibility, effectiveness, and impact of each solution, as well as the resources, constraints, and risks involved. You can use tools such as the Decision Matrix, the SWOT Analysis, or the Cost-Benefit Analysis to help you compare and rank the alternatives.

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Mirza Tanim Hassan Khan

British American Tobacco Bangladesh
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If possible you can simulate different solutions in a small scale so that you can understand how it impacts the whole system. After getting to satisfying result you can scale up.

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Kristian L.

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If it is a simple machine that you know all about, then it is quite straight forward. If the issue is bigger, then it would be best to gather the respective specialists in each area of the flow of the problem that needs to be solved. Then you can more easy find and get the right input from everyone that knows their area.

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Jean-Jacques Schutz

Responsable amélioration continue
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Le meilleur des ingénieurs générera probablement des solutions possibles et déterminera l'option optimale. Cependant, cette solution pourrait rencontrer des défis dans sa mise en ?uvre et son acceptation, justifiant une approche double. Rencontrez le personnel concerné, comprenez les problèmes, encouragez-les à proposer des solutions, puis, avec cette préparation, proposez des options liées à votre enquête. Lorsqu'elles sont à 80%, sollicitez l'aide du personnel rencontré pour faciliter la mise en ?uvre et garantir l'acceptation de la solution.

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El-Houcine ZAFINI

Technicien maintenance central des fluides chez Renault Group | Processus de fabrication
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Pour générer des solutions possibles, brainstormez en équipe ou individuellement, explorez différentes approches, utilisez des méthodes créatives comme le mind mapping, et assurez-vous d'envisager des options variées avant de sélectionner celles qui semblent les plus prometteuses.

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Stanislav Lyubomskyy Pomburidi

Operador de producción en Destinus Spain
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Por lo que observo de las personas es que tienen una prisa exagerada por dar una respuesta. Harán todas las tormentas de idea habidas y por haber pero si no somos capaces de alejarnos del problema y abordarlo desde un estado de conciencia distinto podríamos incurrir en en dar soluciones complicadas a problemas menores.

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3 Implement the best solution

After you have selected the best solution, you need to plan and execute it. You should define the goals, tasks, roles, and timelines for the implementation, and communicate them clearly to the relevant stakeholders. You should also monitor the progress and performance of the solution, and make adjustments as needed. You can use tools such as the Gantt Chart, the PDCA Cycle, or the SMART Criteria to help you manage the implementation.

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El-Houcine ZAFINI

Technicien maintenance central des fluides chez Renault Group | Processus de fabrication
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Pour mettre en ?uvre la meilleure solution, créez un plan d'action détaillé, assignez des responsabilités claires, assurez-vous de disposer des ressources nécessaires, suivez de près le progrès, et soyez prêt à ajuster votre approche en fonction des retours d'expérience.

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Stanislav Lyubomskyy Pomburidi

Operador de producción en Destinus Spain
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Diría que para implementar con cierto éxito una solución es hacer participes a todas las personas posibles que vayan a intervenir en su ejecución y, sobre todo, saber generar compromiso en esas personas. Cuidamos de lo nuestro y desde?amos lo que no lo es.

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Ványolos-Szigeti Viola

Customer Quality Engineer at Payer Industries Hungary Kft.
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All of the ideas, what popped up in your mind, are worth to check to solve the problems. The negative answers are also answers. During the problem solving all of the possible factors are factors until you not clarify the real factors.

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4 Evaluate the results

The final step in the problem-solving process is to evaluate the results and measure the outcomes. You should compare the actual results with the expected results, and identify any gaps, errors, or deviations. You should also collect feedback from the customers, users, or beneficiaries of the solution, and assess their satisfaction and needs. You can use tools such as the KPIs, the Balanced Scorecard, or the Customer Satisfaction Survey to help you evaluate the results.

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El-Houcine ZAFINI

Technicien maintenance central des fluides chez Renault Group | Processus de fabrication
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Vous avez bien résumé la dernière étape du processus de résolution de problèmes. L'évaluation des résultats est cruciale pour mesurer l'efficacité de la solution, ajuster les approches futures et garantir une amélioration continue. L'utilisation d'outils tels que les indicateurs clés de performance et les retours clients contribue à une évaluation plus complète et informée.

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5 Learn from the experience

The problem-solving process does not end with the evaluation, but rather with the learning. You should reflect on what worked well and what did not, and identify the strengths and weaknesses of your problem-solving skills. You should also document and share the lessons learned, best practices, and recommendations for future improvement. You can use tools such as the After Action Review, the Learning Log, or the Knowledge Base to help you learn from the experience.

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El-Houcine ZAFINI

Technicien maintenance central des fluides chez Renault Group | Processus de fabrication
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Pour tirer les le?ons de l'expérience, analysez les succès et les échecs, identifiez les facteurs qui ont contribué à chaque résultat, encouragez la rétroaction de l'équipe, et documentez les enseignements clés. Utilisez ces informations pour améliorer les processus, renforcer les compétences de l'équipe et optimiser les futures initiatives.

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Mirza Tanim Hassan Khan

British American Tobacco Bangladesh
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Keeping the log of issues and solutions will be helpful for the next person and also help you identify similar issues and solving. Also preparing troubleshooting guides will help reduce cost and time.

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Stanislav Lyubomskyy Pomburidi

Operador de producción en Destinus Spain
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Una practica que veo entre las empresas es que no comparten soluciones entre ellas. Veo los mismos problemas y las soluciones son distintas. Quizás las empresas deberían abandonar su isla y conectar con otras.

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6 Keep practicing

The best way to develop your problem-solving skills in manufacturing is to keep practicing them in different situations and contexts. You should seek opportunities to apply your skills to real or simulated problems, and challenge yourself to find innovative and effective solutions. You should also seek feedback and guidance from your peers, mentors, or experts, and learn from their experiences and perspectives. You can use tools such as the Case Studies, the Role Plays, or the Online Courses to help you practice your skills.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Stanislav Lyubomskyy Pomburidi

Operador de producción en Destinus Spain
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Quizás en las empresas emergentes se centren en su recurso más valioso, las mentes que residen en la cabeza de sus empleados, sin embargo, seguimos viendo números en vez de personas.

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How can you develop problem-solving skills in manufacturing?

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2

3

4

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1 Identify the problem

2 Generate possible solutions

3 Implement the best solution

4 Evaluate the results

5 Learn from the experience

6 Keep practicing

7 Here’s what else to consider

Materials Science

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