1st Edition

What's Your Problem? Identifying and Solving the Five Types of Process Problems

By Kicab Castaneda-Mendez Copyright 2013
    191 Pages 12 B/W Illustrations
    by Productivity Press

    191 Pages
    by Productivity Press

    Typically, root cause analysis is taught by explaining a variety of tools that require users to gain considerable experience before being able to apply them correctly in the proper settings. What's Your Problem? Identifying and Solving the Five Types of Process Problems simplifies process problem solving and outlines specific techniques to help you identify the various types of process problems and solve them effectively and efficiently.

    Arguing that there are only five types of process problems, the book explains that the Six Sigma methodology—define, measure, analyze, improve, control (DMAIC)—can be vastly simplified for learning, applying, teaching, and mentoring. It identifies the five types of process problems and describes how to solve them using a three-step procedure:

    • Identify the type of problem
    • Find the root cause
    • Address the root cause

    Describing how to maximize ROI for Lean Six Sigma initiatives, the book:

    • Facilitates the application of Lean and Six Sigma principles to both self-learning and teaching others process improvement
    • Presents time-tested methods to help you reduce start-to-finish improvement/project times
    • Identifies techniques that can shorten the time it takes to complete projects, reduce documentation of projects, and increase overall understanding of your projects

    Outlining proven approaches for seamlessly integrating Lean and Six Sigma methodologies with learning and teaching process improvement, the book will help to improve your courses so that participants acquire essential skills quicker and at lower costs. For the self-initiated, this book will get you identifying and solving the two most common process problems within hours, rather than days or weeks.

    SINGLE UNIT PROCESS IMPROVEMENT
    Principle
    Learning

    Delay-Caused Defect
    How to Identify Delay-Caused Defects
    How to Find Root Causes of Delay-Caused Defects
         Delay Due to Flow Stopping
         Delay Due to Rework
         Delay Due to Nonvalue-Added Actions
         Delay Due to Slow Value-Added Actions
    How to Address Delay-Caused Defects
         How to Address Delay Due to Flow Stopping
         How to Solve Delay Due to Rework
         How to Address Delay Due to Nonvalue-Added Actions
         How to Address Delay Due to Slow Value-Added Actions
    Delay Example 1
         1) Identify Delay-Caused Defect
         2) Find Delay Root Causes
         3) Address Delays
    Delay Example 2
         1) Identify Delay-Caused Defect
         2) Find Delay Root Causes
         3) Address Delays
    Delay Example 3
         1) Identify Delay-Caused Defect
         2) Find Delay Root Causes
         3) Address Delays
    Control to Sustain Performance
    What You Can Do Now
    Endnotes

    Error-Caused Defect
    How to Identify Error-Caused Defects
    How to Find Root Causes of Error-Caused Defects
    How to Address Error-Caused Defects
    Error-Caused Defect Example 1
         1) Identify Error Defect
         2) Find Error Root Cause
         3) Address Error
    Error-Caused Defect Example 2
         1) Identify Error Defect
         2) Find Error Root Cause
         3) Address Error
    What You Can Do Now

    Suboptimality-Caused Defect
    How to Identify Suboptimality-Caused Defects
    How to Find Root Causes of Suboptimality-Caused Defects
         Design of Experiment (DOE)
         Data Collection
         Data Analysis
    How to Address Suboptimality-Caused Defects
    Suboptimality Example
         1) Identify Suboptimality-Caused Defect
         2) Find Suboptimality Root Causes
         3) Address Suboptimality
    What You Can Do Now
    Endnotes

    Unpredictability-Caused Defect
    How to Identify Unpredictability-Caused Defects
    How to Find Root Causes of Unpredictability-Caused Defects
    How to Address Unpredictability-Caused Defects
    Unpredictability Example
         1) Identify Unpredictability-Caused Defect
         2) Find Unpredictability Root Causes
              Prediction Model
         3) Addressing Unpredictability
    What You Can Do Now

    Personal Reason-Caused Defect
    How to Identify Personal Reason-Caused Defects
    How to Find Root Causes of Personal Reason-Caused Defects
    How to Address Personal Reason-Caused Defects
    Personal Reason Example 1
         1) Identify Personal Reason Defect
         2) Find Personal Reason Root Cause
         3) Address Personal Reason Root Cause
    Personal Reason Example 2
         1) Identify Personal Reason Defect
         2) Find Personal Reason Root Cause
         3) Address Personal Reason Root Cause
    What You Can Do Now

    MULTIPLE UNIT PROCESS IMPROVEMENT
    Principle
    Leveling
         Chronic Problems
    Critical Thinking
         Informative Decision Making
         Critical Thinking Questions
         Information
         Tools
              Example
    Summary

    How Do I Know I Have a Process Performance Problem?
    Requirement: Identifying Value
    Current (Baseline) Process Performance
         Random Sampling
         Process Capability
    Desired Process Performance
    The Gap
    Worthiness of Closing the Gap
         Prioritization
    Summary
    Endnotes

    How to Know the Root Cause
    Problem Type: Classifying Potential Problems
    Causal Relationships by Problem Type
    Evidence Confirming the Relationship between Cause and Process Performance
         Delay
         Error
         Suboptimal Setting
              Correlation
              Causation
              Optimization
         Unpredictability
         Personal Reason
    Measurement Error
    Summary
    Endnotes

    How Does the Proposed Solution Work?
    Process Change to Close the Gap
         Process Changes with Mistake-Proofing to Address Root Cause
    Process Changes with Controls to Sustain Improved Performance
    Summary

    How to Know When to Improve Again
    Defect Occurs
    Change in Process Performance
    Change in Stability
    Summary
    Endnotes

    Designing Processes
    Principle
    Methodology
    How Do I Know I Have a Process Performance Problem?
    How Do I Know the Root Cause?
    How Do I Know I Have a Sustainable Solution?
    How Do I Know When I Can Improve Again?

    TEACHING PROBLEM SOLVING
    Principle
    Learning Theories
    Purpose of Teaching
         Course Structure for Optimal Learning
         Empirically Based Teaching Philosophy
    Course Structure
    Curricula
         Suboptimality and Unpredictability Courses
         Personal Reason Course
    Summary
    Endnotes

    Three-Step Procedure Lessons
    Lesson 1: Five Process Problems
    Lesson 2: Requirements
    Lesson 3: Delays
    Lesson 4: Errors
    Lesson 5: Suboptimality
    Lesson 6: Unpredictability
    Lesson 7: Personal Reason

    Critical Thinking Lessons
    Lesson 8: Critical Thinking
    Lesson 9: Delays
    Lesson 10: Errors
    Lesson 11: Suboptimality
    Lesson 12: Unpredictability
    Lesson 13: Personal Reason
    Lesson 14: Design

    Mentoring
    Preparation
    Approach
    Summary
    Recap

    Index

    Biography

    Castaneda-Mendez, Kicab