What Lean Manufacturing methodologies are most effective for problem solving?

Abbreviation for?Plan Do Check Act, which is a model that provides a framework for the improvement of a process or system. It can be used to monitor a single issues or guide an entire improvement project or initiative.

PDSA Plan Do Study Act may be the more apt cycle for a constantly evolving work environment. Check means there is no learning or improvisation in the current cycle. Study indicates a constant improvement

Em minha opini?o, a melhor metodologia é o TPM por possibilitar Educa??o e Treinamento e envolver todos os colaboradores na solu??o de problemas, desde os mais simples até os mais complexos.

From my analysis and 26 years of experience in FMCG Operation I think that the most effective tool to solve problems is DMAIC.It can be broken into small pieces instead of launching a big and complicated scoop.So that you solve the issue piece by piece

this tool is used in all aspects and is so easy to implement and coach others as its very effective in its simplicity so does not frighten folks into using this tool

I think A3 problem solving, managed properly, is really powerful tool to drive problem solving across whole organisation. Scalable solutions are key element to succeed.

La méthode A3 encourage plut?t une communication claire et concise, la réflexion approfondie et une approche systématique de la résolution des problèmes. Elle est largement utilisée dans les entreprises pour traiter efficacement les défis opérationnels et améliorer les processus .

O A3 é eficaz no Lean porque estrutura a solu??o de problemas de forma clara e concisa em uma única folha de papel A3. Esse formato promove a clareza, o foco e a comunica??o eficiente, for?ando os envolvidos a condensar suas ideias e análises. Facilita a colabora??o e a revis?o contínua, sendo uma ferramenta visual que ajuda equipes a entender, acompanhar e resolver problemas complexos de maneira sistemática e integrada.

One important point about the A3 is, after the results, you must have a period to check if the solution implemented is really effective. If the answer is yes, then you can affirm that the A3 project is closed with positive results.

I like to use the A3 when I'm going to make an executive presentation, because on one sheet I have to document the whole process of analyzing a problem. I have typically used the A3 for continuous improvement projects, for CAPEX acceptance (modified A3, following the PDCA) and on other occasions to determine the viability of new products (modified A3).

The 5 whys is the first place I start for problem solving. This method is extremely effective, when used correctly, to drill down to root cause of problems that are not extremely complex and do not have several factors or multiple causes that result in a problem. For more complex problems, I find Ishikawa or fishbone diagrams to be more effective. 8Ds are also more effective for problems that involve manufacturing processes wit a lot of human input.

O método 5 Porquês é eficiente no Lean porque oferece uma abordagem direta e focada para a identifica??o da causa raiz dos problemas. Isso alinha-se com os princípios Lean de eliminar desperdícios e melhorar continuamente, garantindo que as solu??es sejam efetivas e que os processos sejam otimizados de maneira sustentável. Ao envolver a equipe na análise e compreens?o profunda dos problemas, promove um ambiente de aprendizado contínuo e melhoria colaborativa.

O método do 5 porquês é bastante eficiente e auxilia na identifica??o de causas prováveis durante a análise. Eu utilizo muito nas análises de falha de equipamentos. Dessa forma consigo determinar a??es de mitiga??o de forma coerente e que sempre s?o efetivas. Evitando a recorrência da falha.

This is my one of the favorite tools that I use to solve challenges with the business systems or processes. One should ask "why" five times to get to the route. Often I have observed that we get to the root cause by third or fourth why. The caveat is that 5 why has to be used along with data. Whenever we asked the question why and we get the probable answer, it has to be followed by a hypothesis test to prove it.

The 5 Whys approach is best when used as a quick tool to get as close as possible to the root cause so an action can be taken immediately. This can be helpful when working with a group of workers that may not be as familiar with more formal problem solving techniques. It is simple to understand and can be taught in the moment right at the equipment involving the operators, maintenance, supervisors, and any other personnel in helping to uncover each layer of the issue. This can serve as a simple approach for production workers and can be used as foundation for more data driven techniques in the future.

This has been a effective approach for permanent corrective actions. What i like about this is that instead of individual this look for a team based approach. In the shopfloor a team really led by frontline worker under supervision of a process coach, line engineer or production manager can come up with frugal ideas. Secondly since it requires a documented approach (not too extensive) teams can measure progress and even drive continuous improvement plans from this approach.

The 8D (Eight Disciplines) method is a problem-solving approach used to address complex issues and ensure their resolution. It involves eight steps: Define the problem, establish a team, describe the problem, develop interim containment actions, identify root causes, implement permanent corrective actions, prevent recurrence, and recognize the team's efforts. This method is commonly applied in industries like automotive and manufacturing to address quality-related issues and improve processes effectively.

Es muy útil al permitir dejar claro tareas y responsables y asi mismo auxiliar en el seguimiento. Así mismo ver si las conclusiones y acciones han sido efectivas.

Le 8D est l’un des outils simples à utiliser - intuitif ou autoporteur- tout en étant pluridisciplinaire et réussissant à intégrer d’autres outils sur ses différentes étapes comme le 5Why ou le 7M avec un résumé structuré directement prêt pour la diffusion Le 8D est un moyen de prouver que les différents outils de résolution de problème se complètent pour tirer le maximum des forces de l’équipe : respecter chacune des étapes, se laisser guider et gérer chacune d’entre elles avec soin pour tendre facilement vers des pistes et des solutions partagées en consensus

O método 8D (Eight Disciplines) destaca-se como uma ferramenta robusta no Lean Manufacturing para a resolu??o estruturada e sustentável de problemas. Sua abordagem de oito disciplinas, desde a forma??o da equipe até a preven??o de recorrências, proporciona uma estrutura abrangente. O método incorpora análises de causa raiz, implementa??o de a??es corretivas eficazes e verifica??es rigorosas. A ênfase na preven??o de reincidências promove a sustentabilidade das solu??es. A flexibilidade do 8D adapta-se a diferentes contextos, tornando-o uma escolha valiosa para enfrentar desafios complexos e impulsionar a melhoria contínua no Lean Manufacturing.

Depends on condition, type of business and the fact that what kind of issue we are going to trigger, we choose one of these 6 Sigma methods. But I personally prefer DIMAIC since it's a data driven problem-solving technique which emphesizes the need of collaboration and communication with an strong control level. It's used mostly when the problem is complex and the risk value is high. I have participated once in a DIMAIC project of reducing demurrage costs. And we got striking results with an outstanding cost saved!

As few of the experts shared their opinion, in lean manufacturing as part of continual improvements, depending upon the business and the complex nature all of them are effective, But in steel manufacturing ( fabrication) industries, DMAIC is very effective methodology and we have seen very effective, had given substantial improvements and results.

Excelente ferramenta para melhoria de processos, especialmente os processos de produ??o contínua. Tem como revés o fato de utilizar análise estatísticas de dados o que faz com que tenha alta dependencia de um bom banco de dados, o que na ausência deste faz com a dura??o do projeto seja maior.

According to my experience in Lean Manufacturing, all the tools are effective according to the formulation of the problem and its complexity, in particular for me the DAMAIC methodology is the most complete and useful in identifying the problem and providing a solution.

Always use data to rule out assumptions. When you have fact based data, this helps you to follow DMAIC steps in prefer to find the true root cause

The PDCA cycle, A3 method, and 8D method are interconnected problem-solving approaches, each building upon the continuous improvement philosophy. While the PDCA cycle lays the foundational steps, the A3 method expands on this by encapsulating the process on a single A3-sized paper, emphasizing clarity and communication. The 8D method introduces a more structured eight-step discipline, focusing on quality and customer-related issues. All three methods share a common goal of systematic problem resolution, with PDCA serving as the conceptual backbone, A3 enhancing problem-solving with concise documentation, and 8D providing a robust framework for addressing quality control and customer satisfaction.

Think and Observe are Keys to Effective Problem Solving and Method Selection During the thinking process, ask relevant questions and challenge assumptions. This critical thinking approach enables us to explore different perspectives and uncover hidden factors that may be contributing to the problem. By thinking critically, we can avoid jumping to conclusions or making hasty decisions, ensuring a more accurate and comprehensive problem analysis by engaging in deep thinking, we can analyze problems thoroughly, challenge assumptions, and gain a comprehensive understanding of the issue. Embracing thinking and observation as critical steps in problem-solving empowers us to overcome challenges with efficiency, accuracy, and creativity

I absolutely always use a fishbone where possible, it promotes cross functional working on the exploration of all possible root causes for the problem in hand. Problem Solving is always best done as a team to gain all perspectives and possibilities, this is a super simple tool to help facilitate that

They all work effectively. The key is to actually complete them. It takes time, effort , data, commitment etc. People get frustrated when solving a difficult problem is difficult and jump from tool to tool looking for an easy solution. There is no magic wand/tool. Pick one and work the problem until it is resolved.