Problem Solving Flashcards
(13 cards)
What are some problem solving tools?
DMAIC
FMEA
Lean Manufacturing - help solve problems before they start?
Deviation management systems
Define DMAIC?
A data-driven problem-solving cycle
Define
Measure
Analyse
Improve
Control
Describe techniques used in define?
Trying to establish your problem statement
5 Why’s 1 H - Iterative questioning to drill down to the root cause of an issue
Gap analysis (maybe) - What Should Happen, What Did Happen, Gaps Identified, Is/Is not, Why
Fishbone (6M’s)
Describe techniques used in measure?
Collecting data
Doing hypothesis testing to try and prove what you’ve defined
Describe techniques used in analyse?
Brainstorm
Go back to fishbone and Gap analysis
Utilise Data tools: Excel, PowerBI, Origin or AI (machine learning) to find patterns in data.
Describe techniques used in Improve?
Corrective and Preventative Action (CAPA)
Describe techniques used in Control?
CAPA verifier - will check to see if this addresses the root cause
CAPA effectiveness check
Check to see if there have been any deviations of the same instance since
Depending on the problem could use process capability analysis
A statistical method that measures how well a process meets its specifications (CpK is calculated)
1.33 = process is within spec limits and deemed good
Depending on the problem OEE (overall equipment effectiveness) percentage if line issue
What is FMEA?
Failure Mode and Effects Analysis
What does FMEA help with?
It helps with product quality risk assessment
Describe FMEA?
A risk assessment tool
Scores: severity, occurrence and detection (1,4,7,10)
Multiplied together this assigns a risk priority number (RPN)
This can help assign a recommended action based on RPN number
This also uses Pareto analysis to prioritise the risks (working under the assumption that 80% of problems result from 20% of the causes)
What does the tool deviation management systems provide?
Standardise the root cause analysis (RCA)
Allows all documents/tasks/info to be in one place - ease of access and trending
What are some Lean manufacturing tools?
PPM board
5S - sort, set, shine, standardise, sustain
KanBan
Kaizen - collaborative workshop
Poka-yoke - fool proof way to elimate human error (e.g. buzzer/light)
What is a tool MSAT use for continuous process verification?
Trending product quality metrics
Using statistical process control to determine upper and lower limits of metrics
