| Everyone
knows that prevention is better
than cure, but finding a way of escaping the problem solving spiral has
not been easy. Inevitably this infers a greater allocation of resources
for more planning and better prevention. But how can more resources
be allocated to prevention when they are being constantly used for putting
out fires?
Root Cause Analysis
An important
first step is to ensure that current problems are fully resolved and do
not recur.
But problems
are only be fully resolved when corrective actions are taken at their
root cause level. This requires a mind-set focused at finding root causes
rather than symptoms and determining the best actions and controls that
can be practically implemented to totally eradicate the problem.
This is an essential step along the path of Continuous Improvement as
it can expose the changes that can be made to sustain improved productivity.
Structure and Discipline
A number of basic activities must always be addressed to ensure
that deep- seated problems are thoroughly resolved – regardless
of the nature or type of problem being analysed.
Some of these are:
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describing
the problem
analysing effects
identifying (root) causes
generating solutions
selecting best fixes
implementing changes
preventing recurrence |
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If these key factors are not resolved in a logical and sequential way
there is a strong chance that steps will be omitted or that short cuts
will be taken, resulting in an ineffectual resolution and a strong likelihood
that the problem will recur in the future.
The 8-D’s
(8- Disciplines) provides the necessary structure needed for the most
efficient and thorough resolution of systemic problems.
Decision making and SPC
The TOPS process is focused on decision-making based on facts rather than
on opinions. This infers the need to collect and analyse data.
The 8-D’s program has been designed with the application of statistical
tools in mind (e.g. SPC, DOE, etc). Throughout the process specific statistical
tools are highlighted for inclusion in the process. Guidelines are provided
to show when and how they can be best applied throughout.
Selecting the best choice requires an understanding of decision-making
procedures. A number of decision-making strategies are considered for
application in the TOPS program.
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Problem
Solving Teams
Even the
best tools and techniques are rendered useless without correct inputs
from people who have the necessary experience and understanding of the
issues being embraced - or if people are not committed to implementing
remedial actions.
Perhaps the most important ingredient
for the successful resolution of problems is the ability to form teams
and in their ability to apply the necessary steps needed to fully resolve
problems.
The TOPS process provides teams with the necessary analytical and presentation
skills needed for management reviews.
Report Format
In summary the TOPS (8-D’s) program has been developed to:
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aid
in the resolution of problems where the causes are “unknown” |
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establish
a mind-set for solving problems based on facts |
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provide
an effective framework
for the timely application of SPC, DOE, FMEA, Process Controls etc.
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document
the problem solving activities for tracking, reporting and presentation
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For expert
consultation, training and facilitation in this field contact:
Lou
Travella
Design 4 Excellence
Ph/Fx: 61 3 5221 6413
EMAIL:
INFO@DESIGN4EXCELLENCE.COM.AU
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