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Here's how you can master effective problem solving in manufacturing.

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In manufacturing, problem-solving isn't just a skill—it's a necessity. With complex machinery, supply chain logistics, and quality control, issues are bound to arise. But fear not, you can become adept at navigating these challenges. The key is to approach problems systematically and use proven strategies to find solutions that not only fix immediate issues but also prevent future ones. By mastering these techniques, you'll be able to maintain productivity, ensure quality, and keep your operations running smoothly. Let's explore how you can hone your problem-solving skills in the manufacturing sector.

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1 Identify Issues

The first step in effective problem solving is accurately identifying the issues at hand. You need to observe the symptoms of the problem carefully and gather relevant data. This involves talking to the operators on the floor, reviewing production reports, and examining the machinery or processes in question. Only when you have a clear understanding of what is going wrong can you begin to work towards a solution. Remember, correctly identifying the problem is half the battle won.

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Peter Ishimaru, BSQSM, ASQ CMQ-OE, CSSGB, CQIA

Past Chair of American Society for Quality (ASQ) Canton-Akron Section 810 for 2023 -Non-Profit/ Futurist/ Certified Quality Manager/ Auditor/ Risk Assessment and Mitigation, Contingency Planning
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I agree defining the problem is an important element to prevent, correct or improve a process. Using as much data as possible and observations, enhances clarity on identifying the problem. Just as important as clearly identifying and stating the problem, is the solution itself. If the solution or improvement implemented doesn’t work, then, the problem likely wasn’t clearly identified or stated correctly in the first place. If the countermeasure works, it’s a good indication the problem was stated properly.

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2 Root Causes

Once you've identified the problem, it's crucial to dig deeper and find the root cause. Techniques like the Five Whys—a method of asking "why" repeatedly until you reach the underlying cause—can be incredibly useful. This step prevents you from merely addressing symptoms rather than the actual problem, saving time and resources in the long run. It's like treating an illness: alleviating symptoms provides temporary relief, but understanding and curing the disease brings a long-term solution.

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Peter Ishimaru, BSQSM, ASQ CMQ-OE, CSSGB, CQIA

Past Chair of American Society for Quality (ASQ) Canton-Akron Section 810 for 2023 -Non-Profit/ Futurist/ Certified Quality Manager/ Auditor/ Risk Assessment and Mitigation, Contingency Planning
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Identifying root cause depends upon the type of problem and complexity. Using the proper root cause analysis tool can provide a better understanding of the “true root cause” from understanding the symptoms. Along the way, other problems can be potentially found or potential process improvements when investigating. Problems can be caused by multiple process variables (interactions) or multiple root causes thus indicating complexity. Problems and root causes should always be identified in the Failure Mode Effects Analysis (FMEA).

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3 Brainstorm Solutions

With the root cause in hand, it's time to brainstorm possible solutions. Encourage an open and creative environment where all team members can contribute ideas without judgment. The goal is to generate a wide variety of potential solutions before evaluating their feasibility. This collective approach not only leverages diverse perspectives but also fosters a sense of ownership and collaboration among your team, which is essential for successful implementation.

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4 Decision Making

Now comes the critical phase of decision making. Assess each potential solution based on criteria such as cost, time, resources, and impact. It's important to be objective and consider the long-term implications of each option. Sometimes, the best solution isn't the most obvious or easiest one; it requires looking beyond immediate convenience to ensure sustainability and efficiency in your manufacturing processes.

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Peter Ishimaru, BSQSM, ASQ CMQ-OE, CSSGB, CQIA

Past Chair of American Society for Quality (ASQ) Canton-Akron Section 810 for 2023 -Non-Profit/ Futurist/ Certified Quality Manager/ Auditor/ Risk Assessment and Mitigation, Contingency Planning
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When preventative, corrective, or improvement is contemplated, the team (with management support), must decide on what is to be implemented. Ideally, the solution will be cost effective (good ROI), less operator dependent, ensures contractual capacity, has employee buy in (very important element), and is sustainable.

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5 Implement Changes

After deciding on the best solution, it's time to implement changes. This step should be carried out with careful planning and communication. Make sure everyone involved understands their role in the implementation process. It's also vital to establish clear timelines and milestones to track progress. Effective implementation is a meticulous process that can make or break the problem-solving effort.

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Peter Ishimaru, BSQSM, ASQ CMQ-OE, CSSGB, CQIA

Past Chair of American Society for Quality (ASQ) Canton-Akron Section 810 for 2023 -Non-Profit/ Futurist/ Certified Quality Manager/ Auditor/ Risk Assessment and Mitigation, Contingency Planning
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When preventative, corrective, or improvement is contemplated, the team (with management support), must decide on what is to be implemented. Ideally, the solution will be cost effective (good ROI), less operator dependent, ensures contractual capacity, sustainable, and has employee buy in. The “employee buy in” and “customer buy in” on the solution is very important as it can “make or break” an implementation corrective action or process improvement whether effective or not.

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6 Monitor Results

Finally, monitoring results is essential to ensure that the solution you've implemented is effectively addressing the problem. Keep a close eye on the relevant metrics and feedback from the production floor. If the solution isn't working as expected, don't hesitate to revisit earlier steps. Continuous improvement is a cornerstone of manufacturing, and by regularly evaluating the outcomes of your problem-solving efforts, you can refine your approach and enhance your operations.

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Peter Ishimaru, BSQSM, ASQ CMQ-OE, CSSGB, CQIA

Past Chair of American Society for Quality (ASQ) Canton-Akron Section 810 for 2023 -Non-Profit/ Futurist/ Certified Quality Manager/ Auditor/ Risk Assessment and Mitigation, Contingency Planning
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From experience, monitoring the implementation of preventative, corrective, and process improvements is vital. Additionally, periodic audits are necessary to ensure the countermeasures are still in place and the process is not affected negatively. In the past, I created a Corrective Action Verification Audit (CAVA). This was to evaluate sustainability of what was implemented and its impact on the process. The CAVA was conducted as a two person team to evaluate at 30 days after implementation of countermeasures, 90 days, 180 days, and 365 days.

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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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Here's how you can master effective problem solving in manufacturing.

1

2

3

4

5

6

7

1 Identify Issues

2 Root Causes

3 Brainstorm Solutions

4 Decision Making

5 Implement Changes

6 Monitor Results

7 Here’s what else to consider

Manufacturing

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Here's how you can master effective problem solving in manufacturing.

1

2

3

4

5

6

7

1 Identify Issues

2 Root Causes

3 Brainstorm Solutions

4 Decision Making

5 Implement Changes

6 Monitor Results

7 Here’s what else to consider

Manufacturing

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