Develop Practical Problem Solving Capabilities Throughout Your Organization

Develop Practical Problem Solving Capabilities Throughout Your Organization

By Gene Russell, Manex President and CEO

Manex uses a holistic, proven approach to help our clients reap the full benefits from Practical Problem Solving (PPS). PPS eliminates and minimizes non-conformance, which leads to immediate cost savings and quality improvements. In most cases, quality and non-conformance issues can be corrected in three days or less. Manex follows the proven 6 Sigma approach of Define, Measure, Analyze, Improve and Control (DMAIC). PPS yields significant, sustained results by installing a team approach to problem resolution. Manex enables employees to understand the foundational approach to identifying, analyzing and resolving problems through our proven, Teach the Concept, Prove the Concept and Implement the Concept to employees on the shop floor.

 

Approach

Define

  1. Initial problem perception
  • Problem is identified
  • Problem may not be well understood
  • Description of problem may be vague
  1. Develop problem definition
  • Clearly define the “real” problem
  • Understand the standard
  • Discover the deviation
  • Understand the severity of the issue

Measure

  1. Locate point of cause
  • Walk through the process to find the POC
  • When and where the problem is occurring
  • Who is involved
  • Duration and frequency of problem

Analyze

  1. Identify root cause(s)
  • Investigation of the root cause
  • Utilization and analysis – problem solving tools:
    • Cause/Effect
    • Pareto Analysis
    • Process Flow
    • 5Why

Improve

  1. Develop and deploy the countermeasure
  • Temporarily contain the problem

 

  1. Evaluate the countermeasure.
  • Follow-up to ensure countermeasure was effective

Control

  1. Standardize the countermeasure
  • Control and monitor results
  • Countermeasure becomes the standard
  • Educating the workforce is critical

Once the PPS process is successfully completed, the results are used to develop a proactive approach to prevent the re-occurrence of the problem.  Advanced control methods are employed including poka-yoke/mistake proofing, standardized work and failure mode effects analysis (FMEA) programs to name a few, that are used to identify the critical points in the process in which the problem occurred. Manex employs the A3 report as the summary document for each phase of the DMAIC and PPS process. The A3 report is an industry recognized vehicle used to document each phase of the process.

Some of the items captured in the A3 report are:

  • Problem Definition
  • Scope of the Problem
  • Nature of Impact
  • Containment Action Taken
  • Potential Root Causes and Symptoms
  • The Root Cause
  • Current State of the Process
  • Desired Future State of the Process
  • Corrective Actions
  • Effort vs. Impact Matrix to Prioritize the Corrective Actions
  • Roadmap for the Implementation of Corrective Actions
  • Projected vs. Actual Savings Tracker
  • Lessons Learned, etc.

Benefits

  • Address the TRUE root cause and not the symptom of the problem
  • Eliminate the recurrence of the problem
  • Enhance first-pass yield
  • Decrease rework, rejects and warranty costs
  • Improve employee morale
  • Enhance customer satisfaction

 

Manex’s Practical Problem-Solving projects result in more than 600% ROI – that’s a $6 return for every $1 dollar invested in these projects.  For more information, contact Manex at 925.807.5100 or email bizdev@manexconsulting.com.

 

About the Author

Gene Russell is President and CEO of Manex and has over 30 years of senior executive strategic planning, operational management, and consulting experience in the manufacturing and technology sectors. With his extensive knowledge of manufacturing operations, he has developed and implemented key strategic initiatives for companies, allowing them to improve performance and achieve profitable growth. 

2018-01-03T17:18:24+00:00