Course Details

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Learning Objectives

• Describe the foundations for effective Problem Solving
• Describe CQI-20 2nd edition 9 Steps for effective Problem Solving
• Execute Problem Solving Steps 1 to 9
• Develop a robust containment process
• Use the Tool Matrix to select the proper problem-solving tools
• Develop problem solving tools to support a robust completion of each problem-solving steps
• Develop a new and/or adjust your current problem-solving reporting format
• Identify the presence of inhibitors to effective problem resolution
• Use the organizational culture assessment to identify opportunities for improvement of the problem-solving process at the organizational level

Who Should Attend

Recommended for all problem solvers and practitioners responsible for ensuring the effectiveness of the problem-solving process, appropriate application of problem-solving tools, and establishing and reinforcing an effective problem-solving culture.

Typically, this is performed by a multidisciplinary team from the following functions: internal auditors, manufacturing managers, supervisors and team leaders, quality-related personnel, equipment and tooling specialists, supplier quality engineers, laboratory technicians, core tools (MSA, SPC, FMEA, APQP/PPAP) coordinators, logistics related personnel, and anyone who participates in the corrective action and continual improvement processes.

Course Outline

• Problem Solving at a glance
• Problem solving foundations
• Problem solving process
  • Step 1. Becoming aware of the problem
  • Step 2. Establish the team
    • Register the Issue
    • Review the Needs
    • Roles and Responsibilities
    • Problem Solving Team Leader Skills
    • Designate Team
  • Step 3. Describe the problem
    • Gather Information
    • Problem Statement
    • Tools: 5W2H, Check sheet, Is/Is Not, Basic Statistical Tools (Concentration diagram, Pareto Charts, Fishbone, Run Charts, Scatter Plots, Control Charts, Histogram, Capability)
    • Keys to Problem Statement
  • Step 4. Contain symptoms
    • Locate Suspect Material
    • Contain Symptoms
    • Disposition of Suspect Material
    • Tools: Containment Worksheet, Variable and Attribute (Kappa) Gage R&R basics, Check Sheets
  • Step 5. Establish root cause(s)
    • Review Evidence and FMEA
    • Record & Analyze Failure Mode
    • Determine Potential Root Causes
    • Confirm True Root Causes
    • Tools: PFMEA basics, Why-Why / 5 Whys 3 Times / 3-Legged 5 Why, Shainin methodology basics using BOB (best-of-the-best) and WOW (worst-of-the-worst), Basic Statistical Tools (see Step 3)
  • Step 6. Select and test corrective actions
    • Selection of Corrective Actions
    • Testing of Corrective Actions
    • Tools: Basic Statistical Tools (see Step 3)
  • Step 7. Implement corrective actions
    • Verification of Corrective Actions
    • Capability
    • Probability of Occurrence
    • Containment
    • Lessons Learned
    • Tools: Error Proofing / Mistake Proofing / Poka Yoke basics, Basic Statistical Tools (see Step 3), Decision matrix, Lessons learned, Variable and Attribute (Kappa) Gage R&R basics.
  • Step 8. Prevent reoccurrence
    • Develop Replication Plan
    • Replicate Corrective Actions to Similar Processes
    • Institutionalize Corrective Actions
    • Linkage between corrective actions and APQP/PPAP process
    • Tools: Variable and Attribute (Kappa) Gage R&R basics, Basic Statistical Tools (see Step 3), Process FMEA and Control Plan basics, Decision Matrix, Replication/Read-Across, Error-Proofing / Mistake-Proofing / Poka Yoke basics, Is/Is Not for Reoccurrence Prevention, Layered Process Audit (LPA - CQI-8) basics.
  • Step 9. Recognize team success
    • Determine Appropriate Recognition
    • Investigate Intellectual Property
• Inhibitors to effective problem resolution
• Problem solving organizational culture assessment

Delivery Details

Combining the best of online and traditional face-to-face learning, Live Virtual Workshops use web-based teleconferencing technologies to bring your team together with our experienced instructors in an interactive learning environment. We have always believed interactivity, application, and group discussion are critical parts of an effective and sustainable learning experience. To ensure that these values hold true, and every participant can build the same caliber of knowledge, each workshop includes the following Live Virtual functionality and features:

• Trainers & Moderators: For every session, both trainers and moderators will be present and accessible to ensure optimal interaction for each participant, upholding the intimacy of a face-to-face training. Participants can use chat and “raise hand” features, speak directly to trainers, moderators, and other participants, and share their screen all in real-time.
• Exercises & Break-out Rooms: Throughout the session, participants will be assigned to teams and split into team breakout rooms to privately complete group activities and discussions, then return to the larger group to present. There will also be quizzes (polls) throughout to measure knowledge retention throughout the units.
• Digital Learning Package & Shipped Materials: Depending on the course, participants may be mailed a hardcopy of the Participant Training Book and/or receive a digital learning package complete with training handouts, case studies, digital workbooks, and a virtual platform user-guide.
• Technical Support & Resources: New to Live Virtual Training and Consulting technology? We’ve prepared resources and user guides to help you navigate the Zoom Live Virtual conferencing technology and will have live support on-hand just in case you need a little extra help. We'll also allow you to join the session 30 minutes earlier and a moderator will guide you in experiencing the key functionalities and features used in the virtual platform.