What's Your Problem? Identifying and Solving the Five Types of Process Problems: 1st Edition (Paperback) book cover

What's Your Problem? Identifying and Solving the Five Types of Process Problems

1st Edition

By Kicab Castaneda-Mendez

Productivity Press

191 pages | 12 B/W Illus.

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Paperback: 9781466552692
pub: 2012-11-14
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pub: 2017-07-27
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Description

Typically, root cause analysis is taught by explaining a variety of tools that require users to gain considerable experience before being able to apply them correctly in the proper settings. What's Your Problem? Identifying and Solving the Five Types of Process Problems simplifies process problem solving andoutlines specific techniques to help you identify the various types of process problems and solve them effectively and efficiently.

Arguing that there are only five types of process problems, the book explains that the Six Sigma methodology—define, measure, analyze, improve, control (DMAIC)—can be vastly simplified for learning, applying, teaching, and mentoring. It identifies the five types of process problems and describes how to solve them using a three-step procedure:

  • Identify the type of problem
  • Find the root cause
  • Address the root cause

Describing how to maximize ROI for Lean Six Sigma initiatives, the book:

  • Facilitates the application of Lean and Six Sigma principles to both self-learning and teaching others process improvement
  • Presents time-tested methods to help you reduce start-to-finish improvement/project times
  • Identifies techniques that can shorten the time it takes to complete projects, reduce documentation of projects, and increase overall understanding of your projects

Outlining proven approaches for seamlessly integrating Lean and Six Sigma methodologies with learning and teaching process improvement, the book will help to improve your courses so that participants acquire essential skills quicker and at lower costs. For the self-initiated, this book will get you identifying and solving the two most common process problems within hours, rather than days or weeks.

Table of Contents

SINGLE UNIT PROCESS IMPROVEMENT

Principle

Learning

Delay-Caused Defect

How to Identify Delay-Caused Defects

How to Find Root Causes of Delay-Caused Defects

Delay Due to Flow Stopping

Delay Due to Rework

Delay Due to Nonvalue-Added Actions

Delay Due to Slow Value-Added Actions

How to Address Delay-Caused Defects

How to Address Delay Due to Flow Stopping

How to Solve Delay Due to Rework

How to Address Delay Due to Nonvalue-Added Actions

How to Address Delay Due to Slow Value-Added Actions

Delay Example 1

1) Identify Delay-Caused Defect

2) Find Delay Root Causes

3) Address Delays

Delay Example 2

1) Identify Delay-Caused Defect

2) Find Delay Root Causes

3) Address Delays

Delay Example 3

1) Identify Delay-Caused Defect

2) Find Delay Root Causes

3) Address Delays

Control to Sustain Performance

What You Can Do Now

Endnotes

Error-Caused Defect

How to Identify Error-Caused Defects

How to Find Root Causes of Error-Caused Defects

How to Address Error-Caused Defects

Error-Caused Defect Example 1

1) Identify Error Defect

2) Find Error Root Cause

3) Address Error

Error-Caused Defect Example 2

1) Identify Error Defect

2) Find Error Root Cause

3) Address Error

What You Can Do Now

Suboptimality-Caused Defect

How to Identify Suboptimality-Caused Defects

How to Find Root Causes of Suboptimality-Caused Defects

Design of Experiment (DOE)

Data Collection

Data Analysis

How to Address Suboptimality-Caused Defects

Suboptimality Example

1) Identify Suboptimality-Caused Defect

2) Find Suboptimality Root Causes

3) Address Suboptimality

What You Can Do Now

Endnotes

Unpredictability-Caused Defect

How to Identify Unpredictability-Caused Defects

How to Find Root Causes of Unpredictability-Caused Defects

How to Address Unpredictability-Caused Defects

Unpredictability Example

1) Identify Unpredictability-Caused Defect

2) Find Unpredictability Root Causes

Prediction Model

3) Addressing Unpredictability

What You Can Do Now

Personal Reason-Caused Defect

How to Identify Personal Reason-Caused Defects

How to Find Root Causes of Personal Reason-Caused Defects

How to Address Personal Reason-Caused Defects

Personal Reason Example 1

1) Identify Personal Reason Defect

2) Find Personal Reason Root Cause

3) Address Personal Reason Root Cause

Personal Reason Example 2

1) Identify Personal Reason Defect

2) Find Personal Reason Root Cause

3) Address Personal Reason Root Cause

What You Can Do Now

MULTIPLE UNIT PROCESS IMPROVEMENT

Principle

Leveling

Chronic Problems

Critical Thinking

Informative Decision Making

Critical Thinking Questions

Information

Tools

Example

Summary

How Do I Know I Have a Process Performance Problem?

Requirement: Identifying Value

Current (Baseline) Process Performance

Random Sampling

Process Capability

Desired Process Performance

The Gap

Worthiness of Closing the Gap

Prioritization

Summary

Endnotes

How to Know the Root Cause

Problem Type: Classifying Potential Problems

Causal Relationships by Problem Type

Evidence Confirming the Relationship between Cause and Process Performance

Delay

Error

Suboptimal Setting

Correlation

Causation

Optimization

Unpredictability

Personal Reason

Measurement Error

Summary

Endnotes

How Does the Proposed Solution Work?

Process Change to Close the Gap

Process Changes with Mistake-Proofing to Address Root Cause

Process Changes with Controls to Sustain Improved Performance

Summary

How to Know When to Improve Again

Defect Occurs

Change in Process Performance

Change in Stability

Summary

Endnotes

Designing Processes

Principle

Methodology

How Do I Know I Have a Process Performance Problem?

How Do I Know the Root Cause?

How Do I Know I Have a Sustainable Solution?

How Do I Know When I Can Improve Again?

TEACHING PROBLEM SOLVING

Principle

Learning Theories

Purpose of Teaching

Course Structure for Optimal Learning

Empirically Based Teaching Philosophy

Course Structure

Curricula

Suboptimality and Unpredictability Courses

Personal Reason Course

Summary

Endnotes

Three-Step Procedure Lessons

Lesson 1: Five Process Problems

Lesson 2: Requirements

Lesson 3: Delays

Lesson 4: Errors

Lesson 5: Suboptimality

Lesson 6: Unpredictability

Lesson 7: Personal Reason

Critical Thinking Lessons

Lesson 8: Critical Thinking

Lesson 9: Delays

Lesson 10: Errors

Lesson 11: Suboptimality

Lesson 12: Unpredictability

Lesson 13: Personal Reason

Lesson 14: Design

Mentoring

Preparation

Approach

Summary

Recap

Index

About the Author

Kicab Castaneda-Mendez is a business and process improvement professional with 30 years experience as an internal and external consultant to manufacturing, service, healthcare, government, and nonprofit organizations from 21 industries on five continents. He has authored two books and more than 35 articles, spoken at more than 25 conferences, and given more than 50 conference workshops on theory, tools, and applications on achieving performance excellence. He has taught several thousand people at every level from hourly to CEOs and has helped improve processes in the supply chain (marketing, vendors, R&D, engineering, QA/RA, manufacturing, sales), support functions (logistics, HR, IT, legal, finance), and management. He is a three-year Baldrige examiner and five-year Connecticut Award for Excellence senior examiner and trainer. Castaneda-Mendez is a GE-certified Master Black Belt, MBB/BB/GB trainer, and facilitator. He has two master’s degrees (statistics and mathematics), a triple major bachelor’s degree (mathematics, philosophy, and psychology), and a permanent Secondary teaching Certificate (mathematics) all from The University of Michigan.

Subject Categories

BISAC Subject Codes/Headings:
BUS082000
BUSINESS & ECONOMICS / Industrial Management
MED002000
MEDICAL / Administration
TEC032000
TECHNOLOGY & ENGINEERING / Quality Control