Systematic Problem Solving

Systematic Problem Solving: Systematic Problem Solving: Applying Proven Methodologies for Improving and Prioritizing Processes.

This one and a half days Systematic Problem Solving workshop is about learning proven methods that are the best for solving problems and improving processes. This course explores the practical application of scientific methods, such as DMAIC, 8D, PDCA, and PDSA. Students learn about the Six Sigma Define, Measure, Analyze, Improve, and Control (DMAIC protocol for process improvement), the Design for Six Sigma (DFSS) protocols, and how they relate to 8D, PDCA, and PDSA. With that foundation and perspective, students learn the systematic problem-solving tools that are fundamental to any process improvement. The methods taught in this course are helpful whether the ultimate goal is to apply Six Sigma, Lean, or Lean Six Sigma, Statistical Process Control (SPC), Statistical Quality Control (SQC), or to achieve world-class operational excellence.

Day 1 — Root Cause Analysis, Systematic Problem Solving, Corrective Action & The Tools

  • Definitions — Root cause, proximate cause, intermediate cause, containment action, corrective action, and preventive action
  • Structured systematic problem-solving protocols — The Scientific Method, PDCA, PDSA, 8 D, DMAIC, et al. — and what they are truly telling us
  • Problem statement development and objectives
  • Ishikawa Fishbone Diagram to structure our thinking about possible cause and effect
  • Weighting candidate factors and a four square analysis to focus our resources on the most fruitful paths to problem resolution or improvement
  • Pareto Charts — prioritizing our efforts
  • Five Whys — where did the problem originate and where can we intervene?
  • Scatter Diagrams — correlations to help identify the nature of the problem and its possible origin

Day 2 — Process Design Analysis

  • Introduction to process flowcharting for process analysis
  • Value vs. Non–value added process steps
  • Critical to quality (CTQ) and Critical to process (CTP) variables, Key Performance Indicators (KPI)
  • Escape points — testing the process for the ability to recognize problems and make corrections
  • Failure Modes and Effects Analysis (FMEA) – testing the process for vulnerabilities and prioritizing process design improvements
  • Application of the methods in the DMAIC and DFSS protocols for Yellow Belt, Green Belt, and Black Belt Six Sigma certification, or as part of an SPC implementation and Business Process Management for world-class operational excellence

Course Objectives

Upon completion of the workshop, students will understand the fundamental principles for Six Sigma systematic problem solving and leave with an understanding of how the principles apply to Six Sigma, Lean or Lean Six Sigma, Statistical Process Control (SPC), and Statistical Quality Control (SQC).

What Career Paths Benefit the Most From Systematic Problem Solving Workshop?

  • People working with manufacturing or non-manufacturing processes
  • Executive and senior management for public and private, profit and non-profit organizations seeking to achieve operational excellence
  • Administrative personnel who own or participate in process development and execution
  • Manufacturing, Process, Quality, Reliability and Metrology Engineers
  • R&D scientists and engineers
  • Product and process development and design engineers
  • Marketing, financial, and business analysts

Additional Course Notes

Customized and on-site versions of this course are available for organizations desiring to target specific groups or objectives. Examples include: Executive Management; quality and process engineers with an emphasis on how to use statistical methods for problem-solving; equipment operators with a focus on participating in problem-solving teams; marketing and business research personnel with a focus on how to solve problems, and develop improvement projects, in response to survey questions or other research methods.

Prerequisites: No prerequisites

Credit & Follow-Up

Participants who complete this course successfully will earn credit toward Six Sigma Yellow Belt, Six Sigma Green Belt, and Six Sigma Black Belt certification. Participants completing the course will earn the right to return to audit free of charge when the course and classroom space is available.

Credits: 1.5 CEUs