Practice Resolution of Problems in 7 Steps

 

An adequate resolution of the problems is the key to the success of a (TPS). We have seen in previous publications tools and methodologies that Toyota uses to analyze and solve problems. The technique of the 5 why? It is only part of the process. Before its use and to determine the possible causes, it must already be counted with a complete vision of the problem itself.

Given its importance, the process of solving problems in Toyota is completely standardized. Three main stages can be clearly identified:
Stage 1: Understand (“grasp”) the situation. Understand fully and objectively what the problem is. What happens, where it happens and when it happens.
Stage 2: Investigate the causes. Identify and understand all the cause-effect relationships that are at stake.
Stage 3: Establish actions and standardize. Once the causes are identified, it is time to apply measures. If they are effective, they should be standardized and should be part of the process of solving similar problems.
Within these three stages, the seven steps that can be clearly identified can be defined throughout the whole process, which we will analyze briefly.

 

Stage 1: Understand the situation

Step # 1: Initial perception of the problem. At first, every problem seems extremely complex, it is loaded with subjectivities and is not limited enough. If we had to explain it, perhaps we oversize it or we have to use too many words. The definitions in this first instance are usually vague and confusing.
Step # 2: Clarify the problem. Let’s look at the situation with an open mind. How is it different what is happening with what we expect? Here there is only one option: go to the real place where the problem is occurring (al gemba). That is to say, to make henchí genbuchu. Here it is usual to use the dieto and Pareto to list and prioritize the problems according to different criteria, such as: nature, criticism, occurrence.
Step # 3: Define POC. At this stage of the analysis, we need to identify the main causes that gave rise to the problem. The first measure, before analyzing them in detail is to determine what is known as Point of Cause (POC, by Point of Cause). That is to say, to define exactly where the problem occurs (physically) and what is the most likely cause up to now (without too much analysis). This allows us to orient ourselves quite a lot to the final solution and lay the foundation to begin with the analysis of the next step.

 

Stage 2: Investigate the causes

 

Step # 4: Investigate. Carry out an investigation through the technique of (5 Whys). Set an initial problem and ask and answer iteratively five times, why?

 

Stage 3: Establish actions and standardize

 

Step # 5: Set measurements. Depending on the results obtained in the previous step / stage, we define one or more actions to counteract them.

Step # 6: Evaluate. Once the actions have been implemented, a method for their evaluation must be given, which gives us information about their effectiveness.

Step # 7: Standardize. If the measures were effective, from now on they will become part of the process of solving future problems. This point is very important for Toyota. Standardization allows you to have the path paved in similar cases in the future, preventing the reocurrences of errors and saving time and money for analysis. A point in favor, in favor of continuous improvement.

An interesting fact, which Jeffrey Liker gives us: in Toyota, problem solving is achieved with 20% tools and 80% thought. This makes it extremely efficient. Instead, in many companies with systems such as Six Sigma (who boast of using complex analysis tools) this percentage is reversed. This leads to an inefficient system in general.

During the explanation of the steps and steps, we have mentioned various concepts that have already been seen in previous publications.

(Español) PDCA – Investigaciones de desviaciones: Resolución Práctica de Problemas en 7 Pasos

Uso de cookies

Este sitio web utiliza cookies para que usted tenga la mejor experiencia de usuario. Si continúa navegando está dando su consentimiento para la aceptación de las mencionadas cookies y la aceptación de nuestra política de cookies, pinche el enlace para mayor información.

ACEPTAR
Aviso de cookies