eight disciplines problem solving
D0: Preparation and Emergency Response Actions
Plan for solving the problem and determine the prerequisites. Provide emergency response actions.
D1: Use a Team
Establish a team of people with product/process knowledge. Teammates provide new perspectives and different ideas when it comes to problem solving.
D2: Describe the Problem
Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how, and how many (5W2H) for the problem.
D3: Develop Interim Containment Plan
Define and implement containment actions to isolate the problem from any customer.
D4: Determine and Verify Root Causes and Escape Points
Identify all applicable causes that could explain why the problem has occurred.
Also identify why the problem was not noticed at the time it occurred.
All causes shall be verified or proved.
One can use five whys or Ishikawa diagrams to map causes against the effect or problem identified.
D5: Verify Permanent Corrections (PCs) for Problem that will resolve the problem for the customer
Using pre-production programs, quantitatively confirm that the selected correction will resolve the problem. (Verify that the correction will actually solve the problem).
D6: Define and Implement Corrective Actions
Define and implement the best corrective actions. Also, validate corrective actions with empirical evidence of improvement.
D7: Prevent Recurrence / System Problems
Modify the management systems, operation systems, practices, and procedures to prevent recurrence of this and similar problems.
D8: Congratulate the Main Contributors to your Team
Recognize the collective efforts of the team.
The team needs to be formally thanked by the organization.
Problem solving tools
Ishikawa diagram also known as cause-and-effect or fishbone diagram
Pareto chart or Pareto diagram
5 Whys
5W2H (who, what, where, when, why, how, how many or how much)
Statistical process control
Scatter plot
design of experiments
Check sheet
Histograms
FMEA
Flowchart or process map
Complaint system
Corrective and preventive action
failure mode and effects analysis
Fault tree analysis
Quality management system (QMS)
eight dimensions of quality
Problem solving
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