Step 4 – Develop/Select Countermeasures Step 4 – Develop/Select Countermeasures

- Develop best solutions. Use appropriate lean tools. - Develop best solutions. Use appropriate lean tools.
- Work on no more than 3 Root Causes at a time - Work on no more than 3 Root Causes at a time
Step 5 – Implement Countermeasures Step 5 – Implement Countermeasures
- Identify ONE owner for each countermeasure - Identify ONE owner for each countermeasure
- Set an aggressive schedule. Challenge yourself! - Set an aggressive schedule. Challenge yourself!
- Use a project management plan. Stick to it! - Use a project management plan. Stick to it!
Step 6 - Check Results Step 6 - Check Results
- Verify results of each countermeasure individually - Verify results of each countermeasure individually
- Use data, comparing to the Standard and the Goal - Use data, comparing to the Standard and the Goal
Step 7 - Standardize the Process Step 7 - Standardize the Process
- Use Job Instruction and follow a deployment plan 8 Step - Use Job Instruction and follow a deployment plan
- Apply visual systems. Make the abnormal obvious. Problem - Apply visual systems. Make the abnormal obvious.
Step 8 - Recognize & Share Success Step 8 - Recognize & Share Success
- Include all who contributed their time and effort
Solving - Include all who contributed their time and effort
Card
Initial Problem 1) Describe the Problem Initial Problem 1) Describe the Problem
?
? ?
The “Real” Problem
? 5 W’s 1 H
Directly Observe and Clarify Size: Large ?
? ?
The “Real” Problem
? 5 W’s 1 H
Directly Observe and Clarify
Define Points of Cause Define Points of Cause
POC POC
POC 2) Containment Actions POC 2) Containment Actions
Plan
POC Protect the Customer
Paper: Plan
POC Protect the Customer

Why Why
Why
Why
3) Cause & Effect Analysis
Drive to Root Cause
The 5 Why Process
Blaze Orange Why
Why
3) Cause & Effect Analysis
Drive to Root Cause
The 5 Why Process
Why
Why Card Stock Why
Why

4) Develop and Select Countermeasure 4) Develop and Select Countermeasure

Do 5) Implement Countermeasure – Go Do It! Do 5) Implement Countermeasure – Go Do It!
Check 6) Analyze Results Check 6) Analyze Results
Act 7) Standardize the Process Card Final Act 7) Standardize the Process
8) Recognize & Share Success 8) Recognize & Share Success
Rev 3 – 09/5/07
Cut Size: Rev 3 – 09/5/07

3.250” x 5.250”
80% Understanding, 20% Action 80% Understanding, 20% Action
Laminating
Step 4 – Develop/Select Countermeasures Pocket Size: Step 4 – Develop/Select Countermeasures
- Develop best solutions. Use appropriate lean tools. 3 ½” x 5 ½” - Develop best solutions. Use appropriate lean tools.
- Work on no more than 3 Root Causes at a time Staples #: 489534 - Work on no more than 3 Root Causes at a time
Step 5 – Implement Countermeasures Step 5 – Implement Countermeasures
- Identify ONE owner for each countermeasure Rev 3.1 - Identify ONE owner for each countermeasure
- Set an aggressive schedule. Challenge yourself! 03-04-11 - Set an aggressive schedule. Challenge yourself!
- Use a project management plan. Stick to it! Jeff Maling - Use a project management plan. Stick to it!
Step 6 - Check Results 802-288-2515 Step 6 - Check Results
- Verify results of each countermeasure individually - Verify results of each countermeasure individually
- Use data, comparing to the Standard and the Goal - Use data, comparing to the Standard and the Goal
Step 7 - Standardize the Process Step 7 - Standardize the Process
- Use Job Instruction and follow a deployment plan - Use Job Instruction and follow a deployment plan
- Apply visual systems. Make the abnormal obvious. - Apply visual systems. Make the abnormal obvious.
Step 8 - Recognize & Share Success Step 8 - Recognize & Share Success
- Include all who contributed their time and effort - Include all who contributed their time and effort

Initial Problem 1) Describe the Problem Initial Problem 1) Describe the Problem
? ? 5 W’s 1 H ? ? 5 W’s 1 H
? ? ? ?
Directly Observe and Clarify Directly Observe and Clarify
The “Real” Problem Define Points of Cause The “Real” Problem Define Points of Cause
POC POC
POC 2) Containment Actions POC 2) Containment Actions
POC Protect the Customer POC Protect the Customer
Plan Plan
Why 3) Cause & Effect Analysis Why
Why
3) Cause & Effect Analysis
Drive to Root Cause Why Drive to Root Cause
Why The 5 Why Process Why The 5 Why Process
Why Why
Why Why

4) Develop and Select Countermeasure 4) Develop and Select Countermeasure

Do 5) Implement Countermeasure – Go Do It! Do 5) Implement Countermeasure – Go Do It!
Check 6) Analyze Results Check 6) Analyze Results
Act 7) Standardize the Process 7) Standardize the Process
Act
8) Recognize & Share Success Rev 3 – 09/5/07 8) Recognize & Share Success Rev 3 – 09/5/07

80% Understanding, 20% Action 80% Understanding, 20% Action

 8 Steps to Problem Solving 8 Steps to Problem Solving
Æ Plan Æ Do Æ Check Æ Act Æ Æ Plan Æ Do Æ Check Æ Act Æ
A problem is a deviation from a standard A problem is a deviation from a standard
Step 1 - Describe The Problem Step 1 - Describe The Problem
• Identify the team • Identify the team
• Problem Statement • Problem Statement
- Clear, Concise, Measurable, Standard & Deviation - Clear, Concise, Measurable, Standard & Deviation
• Understand the Process Æ Clarify the Problem • Understand the Process Æ Clarify the Problem
- Directly Observe the problem at the front lines - Directly Observe the problem at the front lines
- Ask Why, What, Where, When, Who, How Much - Ask Why, What, Where, When, Who, How Much
- Use data: Paretos,Trends,Histograms,Scatter Plots - Use data: Paretos,Trends,Histograms,Scatter Plots
- Tools to Analyze Æ Determine Points of Cause - Tools to Analyze Æ Determine Points of Cause
• Goal Statement • Goal Statement
- What results will be achieved by what date - What results will be achieved by what date
• Tip Æ Avoid Junk Words, Junk Data • Tip Æ Avoid Junk Words, Junk Data
- Like “various, sometimes, a lot, very, extremely..” - Like “various, sometimes, a lot, very, extremely..”
- Sort, scale, and label charts to show a clear story - Sort, scale, and label charts to show a clear story
Step 2 – Containment Actions Step 2 – Containment Actions
• Short Term, Temporary Corrective Action • Short term, temporary corrective action
Step 3 - Cause & Effect Analysis Step 3 - Cause & Effect Analysis
• Use the 5 WHY’s (Fishbone Diagram) • Use the 5 WHY’s (Fishbone Diagram)
- Ask Why, Why, Why, Why, Why? - Ask Why, Why, Why, Why, Why?
• Understand Causes Æ “The Real Problem” • Understand Causes Æ “The Real Problem”
- Brainstorm with team all ideas and possibilities - Brainstorm with team all ideas and possibilities
- Collect data to prove or disprove possible causes - Collect data to prove or disprove possible causes.
- Man, Machine, Materials, Methods, - Man, Machine, Materials, Methods,
Measurement, Mother Nature Measurement, Mother Nature
KEEP THIS CARD HANDY KEEP THIS CARD HANDY

8 Steps to Problem Solving 8 Steps to Problem Solving

Æ Plan Æ Do Æ Check Æ Act Æ Æ Plan Æ Do Æ Check Æ Act Æ
A problem is a deviation from a standard A problem is a deviation from a standard
Step 1 - Describe The Problem Step 1 - Describe The Problem
• Identify the team • Identify the team
• Problem Statement • Problem Statement
- Clear, Concise, Measurable, Standard & Deviation - Clear, Concise, Measurable, Standard & Deviation
• Understand the Process Æ Clarify the Problem • Understand the Process Æ Clarify the Problem
- Directly Observe the problem at the front lines - Directly Observe the problem at the front lines
- Ask Why, What, Where, When, Who, How Much - Ask Why, What, Where, When, Who, How Much
- Use data: Paretos,Trends,Histograms,Scatter Plots - Use data: Paretos,Trends,Histograms,Scatter Plots
- Tools to Analyze Æ Determine Points of Cause - Tools to Analyze Æ Determine Points of Cause
• Goal Statement • Goal Statement
- What results will be achieved by what date - What results will be achieved by what date
• Tip Æ Avoid Junk Words, Junk Data • Tip Æ Avoid Junk Words, Junk Data
- Like “various, sometimes, a lot, very, extremely...” - Like “various, sometimes, a lot, very, extremely..”
- Sort, scale, and label charts to show a clear story - Sort, scale, and label charts to show a clear story
Step 2 - Containment Actions Step 2 – Containment Actions
• Short term, temporary corrective action • Short term, temporary corrective action
Step 3 - Cause & Effect Analysis Step 3 - Cause & Effect Analysis
• Use the 5 WHY’s (Fishbone Diagram) • Use the 5 WHY’s (Fishbone Diagram)
- Ask Why, Why, Why, Why, Why? - Ask Why, Why, Why, Why, Why?
• Understand Causes Æ “The Real Problem” • Understand Causes Æ “The Real Problem”
- Brainstorm with team all ideas and possibilities - Brainstorm with team all ideas and possibilities
- Collect data to prove or disprove possible causes. - Collect data to prove or disprove possible causes.
- Man, Machine, Materials, Methods, - Man, Machine, Materials, Methods,
Measurement, Mother Nature Measurement, Mother Nature

KEEP THIS CARD HANDY KEEP THIS CARD HANDY