The tree diagram is an excellent tool to use in identifying the root cause of a nonconformance. I believe that any individual involved in the investigation of a nonconformance has his/her preferences as to which tool enables them to get the job done in an efficient and effective manner. For me, some of the benefits of the tree diagram can be summarizes as follows:
1. It clearly lays out the full range of the problem that you are investigating in a systematic, and visually expressive manner. By that I mean, you don’t have to read through multiple layers of jargon to sift out the problem. It is clearly stated in the diagram and you can clearly see how each cause is related to the problem statement simply by following the flow chart.
2. It helps to create focus around the core problem. Oftentimes, investigating teams tend to drift off the core problem they are investigating and begin to discuss other issues that are loosely connected to the problem under investigation.
3. It’s simple. The simplicity of the tree diagram begins with defining the problem statement and then connecting the dots, if you will, by asking the question “why”.
Steps to constructing the perfect tree diagram:
1. Assemble the right core team members
· The selection of team members plays a key role in the effectiveness of the group in investigating the root cause of a given nonconformance.
· You want to be sure that the members of the team are knowledgeable about the problem and can contribute to the discussions
2. Define the problem
· “A problem well stated is a problem half solved” C. Kettering. You need to ensure that the problem is clear, gets to the point of “what is wrong with what,” and is free from conclusions.
3. Construct the tree diagram
· The best tool to use is Microsoft Visio where you can click and drag the boxes onto the sheet
· With the problem statement listed in the “trunk” of the tree, you then construct the branches where you answer the question of “why”
· Remember, you are asking “why” and not “who.” One of the biggest problems that I see in my line of work training others in conducting effective root cause investigations is that they often want to answer “who” as opposed to “why”. I always stress in my trainings that it is not so much about the people, the “who” as it is about the process. If your process is ill-defined, undefined, or otherwise non-existent, it does not matter “who” is running the process. The process is broken and requires fixing.
4. Validate the diagram
· Have your diagram scrutinized by someone intimately knowledgeable about the process but was not part of the core team investigating the nonconformance.
· Ask this individual to review the diagram for completeness and accuracy. Make changes as appropriate
5. Identify the root cause
· Review the completed tree diagram and identify those issues where process improvements are required.
· The issues listed at the end of the “why” branch are often the ones that will identify the root cause of the problem. These are often process-related issues and are where you will get the “biggest bang for your buck.”
Wednesday, May 5, 2010
Wednesday, April 14, 2010
Keeping the Focus on Key Problems
At any given day, a manufacturing or production environment will experience a myriad of problems with different levels of risk or urgency. Determining which problems require further investigation and resolution is a challenge faced by many well-meaning managers. The good news, however, is that there are a few tried and true tools of the trade that may be used to help identify and focus on key problems that require quick resolution. The first tool is:
1. Pareto Chart
Pareto chart is a great tool to use when your goal is to focus in on the problems which offer the greatest potential for improvement. In its simplest form, a Pareto chart is a bar graph chart showing the relative frequencies of each issue under evaluation and showing the relative frequencies. Pareto charts will show you the relative importance of problems in a simple, easily interpreted and visual format. This tool is excellent in helping the team remain focused on issues with the greatest impact that will provide the highest yield. I like to say that it is the tool that shows you where you will receive the “biggest bang for your buck”.
Oftentimes, management can become so overwhelmed by the many issues plaguing their departments that they will put valuable resources (i.e., time, personnel and financial) on several insignificant issues while the more pressing issues remain untouched and unresolved. The Pareto principle states that “20% of the sources cause 80% of the problem”. Therefore, it is imperative that you have a methodology to evaluate the many problems facing the department and focusing in on the top 20% or even top 10% which causes 80% of your problems.
Next week’s blog, I will cover how to effectively perform a Pareto on a given problem. Happy Investigating!
1. Pareto Chart
Pareto chart is a great tool to use when your goal is to focus in on the problems which offer the greatest potential for improvement. In its simplest form, a Pareto chart is a bar graph chart showing the relative frequencies of each issue under evaluation and showing the relative frequencies. Pareto charts will show you the relative importance of problems in a simple, easily interpreted and visual format. This tool is excellent in helping the team remain focused on issues with the greatest impact that will provide the highest yield. I like to say that it is the tool that shows you where you will receive the “biggest bang for your buck”.
Oftentimes, management can become so overwhelmed by the many issues plaguing their departments that they will put valuable resources (i.e., time, personnel and financial) on several insignificant issues while the more pressing issues remain untouched and unresolved. The Pareto principle states that “20% of the sources cause 80% of the problem”. Therefore, it is imperative that you have a methodology to evaluate the many problems facing the department and focusing in on the top 20% or even top 10% which causes 80% of your problems.
Next week’s blog, I will cover how to effectively perform a Pareto on a given problem. Happy Investigating!
Wednesday, March 31, 2010
Problem Solving Tool Selection
Previously, I discussed some key elements to Problem Solving involving the analysis of several key components of root cause determination in order to effectively solve the problem. Namely, an Accurate Determination of the Problem, Selecting the Appropriate Problem Solving Tool(s), and an analysis of when to use each tool. Here, I will provide you with 3 additional tools that may be used in order to effectively determine the root cause of a given nonconformance:
1. Affinity Diagram
Affinity diagram is another great tool to use because it allows the team to brainstorm a significant number of ideas relating to an issue and then group and summarize them in order to fully understand the essence of the problem, hence the solutions. I like to use Affinity Diagrams as a problem solving tool because it gives each team member the opportunity to be completely open to ideas that one may not necessarily be aware of. It is also a great tool for overcoming team stagnation.
2. Check Sheet
Check Sheets are best used in counting and accumulating data associated with a process. It allows team members to systematically record and compile data in order to effectively identify trends. This compilation of data creates a clear picture of the elements of the process and allows patterns in the data to become clearly and quickly evident.
3. Histogram
Histogram is a great tool to use in summarizing data from a process over a period of time. This data is then graphically presented in bar form showing the frequency distribution. Histogram is a great tool to use when you want to display large amounts of data in tabular form. This may prove to be of great benefit because graphical representation of data may sometimes be difficult to interpret and having this data represented in a tabular format renders it more easily understood. Histogram also quickly illustrates the underlying distribution of the data which in turn may provide useful information for predicting future process performance. Which tool to use? Depends on the nature of the nonconformance. Happy Investigating!
1. Affinity Diagram
Affinity diagram is another great tool to use because it allows the team to brainstorm a significant number of ideas relating to an issue and then group and summarize them in order to fully understand the essence of the problem, hence the solutions. I like to use Affinity Diagrams as a problem solving tool because it gives each team member the opportunity to be completely open to ideas that one may not necessarily be aware of. It is also a great tool for overcoming team stagnation.
2. Check Sheet
Check Sheets are best used in counting and accumulating data associated with a process. It allows team members to systematically record and compile data in order to effectively identify trends. This compilation of data creates a clear picture of the elements of the process and allows patterns in the data to become clearly and quickly evident.
3. Histogram
Histogram is a great tool to use in summarizing data from a process over a period of time. This data is then graphically presented in bar form showing the frequency distribution. Histogram is a great tool to use when you want to display large amounts of data in tabular form. This may prove to be of great benefit because graphical representation of data may sometimes be difficult to interpret and having this data represented in a tabular format renders it more easily understood. Histogram also quickly illustrates the underlying distribution of the data which in turn may provide useful information for predicting future process performance. Which tool to use? Depends on the nature of the nonconformance. Happy Investigating!
Tuesday, March 23, 2010
Elements of Problem Solving
Problem Solving or Root Cause determination requires the analysis of several key components in order to effectively solve the problem. Here are 3 elements of the key components:
1. An Accurate Determination of the Problem
“A problem well stated is a problem half solved” Charles Kettering (American engineer, inventor of the electric starter, 1876-1958). The criticality of clearly identifying the problem statement is that it helps you (and your team members) to maintain razor-like focus on the issue at hand. There is a tendency to wander outside of the scope of the problem you are investigating once team members become involved. Therefore, it is important that all team members work diligently on clearly identifying the problem at hand and work as a cohesive unit to determine the root cause.
2. Selecting the Appropriate Problem Solving Tool
There is a multitude of problem solving tools/methodologies out there for analyzing a problem. Often, team members are not well-versed in the different tools and when it is appropriate to use them. As a result, they will use a tool that may not be the best fit and end in long discussions around symptoms of the problem but never arriving at an accurate root cause determination. Some of the more popular tools/techniques are as follows:
i) Brainstorming
ii) Cause and Effect Diagram (a.k.a Fishbone Diagram)
iii) Tree Diagram
3. When to Use it?
i. Brainstorming is often used as a primary means of establishing a means for the team to generate numerous ideas as to why an event occurred. Team members throw out ideas in a non-judgmental and encouraging atmosphere. This encourages “open thinking”, enthusiasm, and creativity.
ii. Cause and Effect Diagram (a.k.a Fishbone Diagram) this tool is often used to explore issues that are multi-factorial in nature and help team identify causes of the problem as opposed to symptoms of the problem. It enables team members to focus on the problem, identify the various elements that may contribute to the problem, and builds consensus.Tree Diagram displays the issue at hand and its related causes in a flow chart format that continues to ask the question “why”. It helps team members focus on issues contributing directly to the problem. Team members are able to graphically evaluate the causes of the problem, investigate and systematically arrive at a root cause.
iii. Tree Diagram displays the issue at hand and its related causes in a flow chart format that continues to ask the question “why”. It helps team members focus on issues contributing directly to the problem. Team members are able to graphically evaluate the causes of the problem, investigate and systematically arrive at a root cause.
Marie
1. An Accurate Determination of the Problem
“A problem well stated is a problem half solved” Charles Kettering (American engineer, inventor of the electric starter, 1876-1958). The criticality of clearly identifying the problem statement is that it helps you (and your team members) to maintain razor-like focus on the issue at hand. There is a tendency to wander outside of the scope of the problem you are investigating once team members become involved. Therefore, it is important that all team members work diligently on clearly identifying the problem at hand and work as a cohesive unit to determine the root cause.
2. Selecting the Appropriate Problem Solving Tool
There is a multitude of problem solving tools/methodologies out there for analyzing a problem. Often, team members are not well-versed in the different tools and when it is appropriate to use them. As a result, they will use a tool that may not be the best fit and end in long discussions around symptoms of the problem but never arriving at an accurate root cause determination. Some of the more popular tools/techniques are as follows:
i) Brainstorming
ii) Cause and Effect Diagram (a.k.a Fishbone Diagram)
iii) Tree Diagram
3. When to Use it?
i. Brainstorming is often used as a primary means of establishing a means for the team to generate numerous ideas as to why an event occurred. Team members throw out ideas in a non-judgmental and encouraging atmosphere. This encourages “open thinking”, enthusiasm, and creativity.
ii. Cause and Effect Diagram (a.k.a Fishbone Diagram) this tool is often used to explore issues that are multi-factorial in nature and help team identify causes of the problem as opposed to symptoms of the problem. It enables team members to focus on the problem, identify the various elements that may contribute to the problem, and builds consensus.Tree Diagram displays the issue at hand and its related causes in a flow chart format that continues to ask the question “why”. It helps team members focus on issues contributing directly to the problem. Team members are able to graphically evaluate the causes of the problem, investigate and systematically arrive at a root cause.
iii. Tree Diagram displays the issue at hand and its related causes in a flow chart format that continues to ask the question “why”. It helps team members focus on issues contributing directly to the problem. Team members are able to graphically evaluate the causes of the problem, investigate and systematically arrive at a root cause.
Marie
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