training structured problem solving by experts, general, 13 05-06

Hannover – 06. May 2013

Training on Structured Problem Solving

“A job for Sherlock Holmes & 13 tools …”

Presentation material by B. Krueger

and Experts

Continental - Tire Division

Learning targets

No. 2 / B. Krueger / 6/6/2013 © Continental AG

Introduction


Expectations


Introduction

Add your flip chart here


Agenda “training on structured problem solving”

1. What is structured problem solving …

• 6 steps of structured problem solving

2. How to do structured problem solving …

• the process and the tools - with exercises

3. When structured problem solving should be carried out

and Who is responsible …


Introduction


Chapter 1

What is

structured problem solving …

6 steps of structured problem solving

What is a problem?

Why structured problem solving?


Chapter 1 – Why structured problem solving …


Chapter 1 - Let’s start with a practical exercise

What is structured problem solving?


Chapter 2 – How to do structured problem solving …

Do you know this guy?


Chapter 1 -6 steps of structured problem solving and the corresponding tools



Chapter 2

How to do structured problem

solving …

• the process

• the tools

• the workflow and the “tool package”




Chapter 2 –The process of structured problem solving

… which tools should be used?

how to do it?



Qualitative model from 2 3

Quantitative model from 3 4


Step 1 – Define the problem



Step 1 - Tool package A




Step 1 – Exercise


Create a checklist to describe a

problem

It will help you later on

to gather all needed information

let’s start –

10 minutes time to finish


Step 1 – Summary on steps to define the problem



Step 2 – Analyze the problem



Step 2 – Find the root cause … Starting analysis - find cause




Step 2 – Tool package “B”to find the cause



Step 2 – Find the root cause … Starting analysis - find cause / Tool “Is – Is not”

Gather more facts; do is – is not

Example




Step 2 – Find the root cause … Starting analysis - find cause / Tool “Is – Is not”

Gather more facts; do is – is not

Example blemishes on sidewall of 275/70 R16 in PE




Step 2 – Fishbone

Do Fishbone, score on main causes, formulate hypothesis and verify them




Step 2 – Tips: How to do the Fishbone

1. Do the Fishbone together with your team

2. Write the problem statement into the “fish head”

3. Clarify major categories

4. Let the team brainstorm to identify possible causes of the problem

5. Use brainstorming rules to run the Fishbone session

6. Write down all ideas

7. Don’t get hung up with which categories to use as long as all the ideas are captured

8. After brainstorming vote on the most reasonable cause (1 to 3 dots/person)

9. Formulate hypothesis on main causes

10. Check hypothesis against already known facts

11. Verify hypothesis, define how and who should do it



Let’s practice together!


Step 2 – Exercise



1. Do Fishbone on potential causes …

2. Score on main causes

3. “Formulate hypothesis” on main cause and how to verify

let’s start –



Step 2 –preparation for your Fishbone”: explain the facts of the problems


Place your example description from the

flip chart here!


Step 2 –your “Fishbone” and scoring on main causes


Place your example from the flip chart here!


Step 2 –Hypothesis and verification of your cause


Place your example from the flip chart here!


Step 2 – Verification of hypothesis vs. facts

Example blemishes on sidewall of 275/60 R16 in PE



1 2 3 4 5 6

Rating

(sum) comment

5 Compression of sidewall in bobbin 3 1 3 3 5 3 18 If sidewall is squeezed in the same position that

the problem occurs, there is a suspicion that this

is causing blemishes

Check sidewall for hi-point

corresponding with position on tire.

xx

6 curing bladder type 1 1 5 5 5 1 18 Bladder cannot affect blemishes in an unequal

way

Confirm the bladder allocation is

correct / alternatives

xx

7 1st stage stitching pressure 1 1 3 5 5 5 20 If stitching / stitching pressure is affecting the

"problem area", we must investigate the

process

Confirm if the stitching is deforming the

sidewall

xx

8 shaping pressure (curing) 3 1 5 5 5 1 20 Depending on whether the presses are all set

up the same

Do trial running max & min pressures xx

9 lift ratio 3 1 5 5 5 5 24 Pinch test xx

10 Sidewall profile (junction) 3 3 5 5 5 5 26 Sidewall will influence all molds, can influence

90% of tires & should always be in the same

location

11 sidewall spec (profile) 3 3 5 5 5 5 26 Sidewall will influence all molds, can influence

90% of tires & should always be in the same

location

xx xx

Possible causes from "Fishbone"

brainstorming

# Verification of hypothesis (potential causes) against facts form the "Is - is not" problem description actions for verification owner


Tool package “C”to find the root cause



includessteps

27

WHY

WHY

WHY

WHY

root cause level 1

level 2

level 3

level 4

WHY

Problem identified

Step 2 – The 5 Why principle to find the root cause …

From cause to root cause


Step 2 – The 5 Why principle to find the root cause …


1. Note problem description

2. Ask 5 (several) times “why” to find the root cause

or ask :

“what is the reason, that …”

“how could it happen, that …”

start with the proven cause

3. Define actions

- Immediate actions to fix the symptom/cause

- Permanent corrective actions to fix the root cause



Step 2 – Example “5 Why”



“Why were the Eurovents blocked?”

-> due to oil in the mold

“Why was oil in the mold?”

-> because the press was leaking

“Why was the press leaking?”

-> because the hydraulic cylinder was leaking

Why was the hydraulic cylinder leaking?

327 tires, size 2014 with faulty sidewall splice out of press J1 within

the last week . Cause: Mold was dirty; the Eurovents blocked.

-> cylinder maintenance not part of regular check


Step 2 – Exercise 5 Why


Complete the 5Why form with an example of a problem

which recently occurred in your working area

let’s start –


Chapter 2 – How problems should be solved


Step 2 – examples of “5whys”



Step 2 – Summary on steps to analyze the problem



Step 3 – Work out remedies


Qualitative model from 2 3


Step 3 - Poka Yoke


= solutions (fool or mistake proven) to prevent doing a mistake

Examples:

our SIM card has a cut corner to

ensure correct insertion in cell phone

in our area and still under discussions –

new DOT code plates

old with pin new – D-shape



Step 3 – Summary on steps to work out remedies



Step 4 – Select, plan actions


Quantitative model from 3 4


Step 4 – Summary on steps to select and plan the actions



Step 5 – Implement, follow up on progress



Step 5 – Summary on steps to implement, follow up on progress



Step 6 – Check, reflect, standardize



Step 6 – Tips: How to check, reflect, standardize

1. check on effectiveness of your remedy by control / trend

charts

2. define triggers to have for the future an early warning system


Please note: have checklist

not to forget any document

Check,reflect, standardize

6

3. should there be any changes to the Best Operating Practice?

reflect, standardize, update your documents

changes may be required to

• work instructions

• procedures

• drawings

• one-point-lesson





Check,reflect, standardize

6

Step 6 –


Chapter 3

When structured problem solving

should be carried out and

Who is responsible for structured

problem solving …


Chapter 3 – When structured problem solving should be carried out …


your contact partner and further support

Britta Krüger

QM – CBS BU Coach Central Functions & BU OE

Phone: +49 511 976 34867

Email: [email protected]

Experts:

Axel Becker +49 511 976 3521

Raymund Lederhofer +49 511 976 3289

Carsten Schroeder +49 511 976 3228

Heiner Volk +49 511 976 3501

Klaus Wiese +49 511 976 3902


end

training structured problem solving by experts, general, 13 05-06

Documents

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process of structured

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