How do you test and validate your solutions before implementing them in the manufacturing process?
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The first step is to clearly define the problem you want to solve and the requirements you need to meet. For example, you might want to reduce defects, increase output, or improve customer satisfaction. You should also consider the constraints and risks involved, such as budget, timeline, regulations, and environmental factors. By identifying the problem and the requirements, you can set the scope and the goals of your solution.
The next step is to brainstorm and research possible solutions that can address the problem and the requirements. You can use various tools and techniques, such as SWOT analysis, 5 Whys, fishbone diagram, or TRIZ, to generate and evaluate ideas. You should also consult with your team, customers, suppliers, and experts to get feedback and insights. You should aim to narrow down your options to the most feasible and effective ones.
The third step is to design and prototype your solution based on the selected option. You should use a systematic and iterative approach, such as design thinking or agile methodology, to design and prototype your solution. You should also follow the best practices and standards of your industry and organization, such as ISO or Six Sigma. You should create a prototype that can demonstrate the key features and functions of your solution.
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Siempre es recomendable tener un ambiente controlado y generar y probar los prototipos en ese ambiente para saber si pueden ser confiables, posteriormente se puede ir mejorando la solución mediante la retroalimentación que se va teniendo de las pruebas que se van ejecutando. Esto nos permite elaborar de manera correcta la validación del prototipo y dar solución precisa al problema
The fourth step is to test and validate your prototype against the problem and the requirements. You should use various methods and tools, such as experiments, simulations, surveys, or focus groups, to test and validate your prototype. You should also collect and analyze data, such as performance indicators, feedback, or errors, to measure the effectiveness and efficiency of your prototype. You should also identify and address any issues or gaps in your prototype.
The fifth step is to refine and optimize your solution based on the test and validation results. You should use a continuous improvement process, such as PDCA or DMAIC, to refine and optimize your solution. You should also apply the principles of lean manufacturing or kaizen, such as eliminating waste, reducing variation, or enhancing value, to optimize your solution. You should also document and communicate your changes and updates.
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During this stage, it is good to have a meeting within various functions and inform them about the proposed changes. There will be high chance of getting good suggestions from other teams which can add value to your solution.
The final step is to implement and monitor your solution in the manufacturing process. You should use a project management framework, such as PMBOK or PRINCE2, to plan and execute your implementation. You should also use a change management strategy, such as ADKAR or Kotter's model, to manage the impact and resistance of your implementation. You should also use a quality management system, such as QMS or TQM, to monitor and control your solution.
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