What do you do if your manufacturing process is facing a complex problem?

In a manufacturing plant producing electronics, a sudden increase in product defects is noticed. The team gathers to analyze the problem thoroughly. They scrutinize the issue from all angles, questioning whether it's a one-time incident or a recurring issue. Beyond the immediate complication, they review production data, consult engineers, and examine defective products. Through this comprehensive approach, they discover that the defects stem from a change in supplier for a critical component, leading to inconsistencies in product quality. With this understanding, they devise a solution involving renegotiating supplier contracts and implementing stricter quality control measures to ensure consistent product quality.

One of the steps that has been helpful is to differentiate facts from fiction. How to do that ? 1. You start your brainstorming. 2. Use the Ishikawa diagram to define the contribution for each area 3. Go and validate it. 4.Came back with data and define the issue

The first step is to thoroughly analyze the problem. Gather your team and scrutinize the issue from every angle. What is the nature of the problem? Is it a one-off incident or a recurring issue? Look beyond the immediate complication to understand its root cause. This may involve reviewing production data, consulting with engineers, or examining the affected product. A comprehensive understanding is vital for developing an effective solution.

Many complex problems, on current production processes, commonly appears when some basic required factor needed is out of control or even not under any control. In my career, much of the factors found as non good condition were related to raw materials and facilities issues. The most important thing, is identify basic factors to be under control and keep efforts to maintain the controls.

Uma abordagem que eu e nossa empresa de Consultoria usamos bastante é uma boa combina??o de FTAs (Fault Tree Analysis = Análise da árvore de Falha, desdobrando bastante a árvore de Falhas com um time verdadeiramente multifuncional), Planos de A??es 5W2H’s (formalizando e executando rápido as a??es) e em paralelo, ir implementando Controles (mais robustos e mais preventivos), na Gest?o à Vista, bem perto dos Executantes das atividades, com o adequado Treinamento.

Involvement of your team is key in problem-solving. Encourage open communication and brainstorming sessions where team members can contribute ideas and share experiences. This collaborative approach not only fosters a sense of ownership among the team but also brings diverse perspectives to the table, increasing the likelihood of identifying a creative and practical solution to the manufacturing problem.

After identifying potential solutions, it's time to implement fixes. Start with the most viable option and monitor the results.Remember, the goal is not just to fix the problem temporarily but to ensure that it doesn't recur.

Testing thoroughly is crucial before fully integrating the solution into your manufacturing process. Conduct trials to ensure that the fix is effective and does not introduce new issues. This step may require time and patience, but it's essential for maintaining quality and efficiency in your production line.

Once you've implemented and tested your solution.Keep an eye on key performance indicators to ensure that the fix has not only resolved the issue but also that it hasn't negatively impacted other areas of your process. Continuous monitoring allows for quick action if any new problems arise and helps maintain the integrity of your manufacturing operations.

In addition to thorough problem analysis and team involvement, it's essential to prioritize safety measures throughout the problem-solving process. Ensuring the well-being of our team members and maintaining compliance with industry regulations are paramount considerations. Furthermore, documenting each step taken and the corresponding outcomes is crucial for future reference and continuous improvement initiatives. This meticulous record-keeping helps track progress, identify patterns, and refine strategies for addressing similar challenges in the future.