Constantly employing short-term fixes, rather than true solutions, wastes time and resources, and diminishes continuous improvement efforts that are vital to on-going competitiveness. With Problem Solving, your operator teams will learn how to detect problems before they occur and alleviate chronic problems within your organization. This one-day workshop teaches different problem solving techniques in a structured, team-based, analytical environment that is needed in any manufacturing organization to detect, fix and stop problems in their track.

First, participants will learn the role of process and product variation in contributing to defects. Then your team will be taught the four-step PDCA (Plan, Do, Check, Act) process in addition to several problem solving tools and methods. Lastly, prevention methods and mistake proofing approaches and guidelines will be learned and practiced. A dynamic, interactive, and effective training method using simulation exercises as a hands-on learning tool ensures participants not only learn a powerful problem solving approach, but are energized about tackling problems in their work area.

Participants will engage in hands-on application of several problem solving tools and techniques, including process mapping, cause & effect diagrams, brainstorming, affinity diagrams, 5 whys, histograms, 20 questions, run charts, A3, and Pareto analysis. Also, live simulations using toy catapults are used to help participants understand the concept of variation and stability.

Project Objectives

• Gain an in-depth understanding of the four-step PDCA process
• Understand how to use multiple problem solving tools and methods
• Reduce process and product variation and consequent defects
• Use prevention methods and mistake proofing approaches and guidelines to stop problems before they occur