Problem Solving and Process Improvement

 

Upcoming Courses

Overview

This course provides participants with an overview of basic problem solving with an emphasis on the effective use of quality tools and root cause analysis. A five-step approach to problem solving is presented, encouraging the necessary “closed loop” thinking that drives better problem solutions and facilitates improvement.  Data collection and data analysis tools are briefly described leading to improved communication about problems and fostering efficient problem solving. Examples are drawn from a metalcasting environment. Participants will be able to assess their own problem solving methods for gaps as they survey the sequence and systems approach presented to resolve quality problems.  

Learning outcomes

At the end of this course, participants should be able to:

  • Describe structured problem solving approaches.
  • Develop effective problem definitions.
  • Describe process behaviors and identify process inputs and outputs.
  • Distinguish between expected and unexpected process performance.
  • Explain why process stability is required for improvement.
  • Characterize problems to develop possible root causes.
  • Recognize various methods for collecting and analyzing data.
  • Determine process improvement solutions and countermeasures (short-term vs. permanent).
  • Implement corrective action to sustain improvement.

Course Length

0.5 days

CEU Units

0.60 CEU

Course outline

Basic Concepts and Problem Definition
  • Structured Problem Solving for Metalcasting Facilities
  • Problem Solving Basics
  • Effective Problem Definition
Teams, Project Management, and Process Thinking
  • The Project Team
  • Process Thinking
  • Understanding Process Variation
Driving Toward Root Cause
  • Root Causes
  • Tools for Identifying Possible Root Cause
  • Problem Solving Group Activity
The Nature of Data
  • Types of Data Used
  • Distributions
  • Using Statistics to Understand Your Data
Collecting and Analyzing Data
  • Measurement Uncertainty
  • Analyzing and Presenting Data
Process Stability and Capability
  • Is the Process Capable of Consistently Meeting Customer Requirements?
Testing the Root Cause
  • Testing the Root Cause
Closing the Loop: Implementing and Monitoring Changes
  • Developing Solutions
  • Evaluating Solutions
  • Sustaining the Improvement
  • Long-term Process Monitoring