Problem Solving Training

This course was developed by David Meier to teach the fundamentals of Problem Solving. The course can be structured in a variety of ways, from a 1-day introductory course to a 4-day course that includes application on specific problems at your company.

In many cases Lean Manufacturing is implemented because operational improvement is desired, however, a clear connection between the desired improvement and the Lean Tools is not always established.  The Problem Solving Methodology provides a mechanism to make that connection and to apply Lean practices to real world problems giving the implementation clear value.  In addition a not so subtle reality of Lean Manufacturing is that if applied properly it will force the awareness of problems, and continued success requires the ability to solve problems.  The Problem Solving Methodology is useful on 2 fronts during a Lean implementation:

1. As a framework for the implementation of Lean tools this method leads to improvements that strengthen the operation and provide satisfaction to employees and customers.

2. A practical method for resolving problems that will surface as a result of Lean methods.

This course will guide students through a systematic flow beginning with a clear understanding of the current situation and the overall impact on process performance.  A careful analysis of facts is absolutely essential to narrow the scope of problems to the most significant, and to prevent a “shotgun” approach to the problem.  Effective analysis begins with the “5 Why” process and results in the identification of “root causes” of the problem.  Sound root cause analysis leads to a clear understanding of appropriate corrective action.  Results of actions are verified and if the goal is successfully achieved the next problem is tackled.  If the desired results are not achieved the problem is re-evaluated and new corrective actions taken and verified.

• Learn a systematic approach for Problem Solving

• Learn how to apply the Lean tools to solve real world problems

• Receive Problem Solving forms and templates

• Review several examples of common issues many companies face

• Learn to build teamwork with this activity

• Learn a common language for communicating activities and results

• Understanding the Lean System and the importance of problem identification and solution

• Using an A3 presentation format

• Defining a problem and clarifying the desired improvement

• Utilization of data to show the extent and impact of the problem

• 5 Why analysis and root cause identification

• Verification of results and developing future activities required to achieve goals

This course is excellent for anyone charged with leading the Lean transformation, or any managers that have responsibility for improving process results.  The Problem Solving method also makes a great Team Building activity and anyone responsible for developing effective teams would benefit from this course.  If you would like to develop a systematic method for attacking problems and finally eliminating them you would also benefit from this course.

All trainers for this course have practical experience gained from working at Toyota and understand how to apply Toyota’s problem solving method in the work place.

Please contact us to discuss the details for applying TWI in your company.