Summary
In summary, the following eight steps are required to solve problems simply and successfully:
Adequately and completely define the problem.
Define the fault characteristics.
Construct a concept sheet to augment a plan of attack.
Develop a plan of attack.
Collect accurate data that is relevant to the study.
Choose and use analysis tools (observations).
Use innovative analysis tools (easy-to-use comparisons).
Establish consistent work and many-level reviews.
Preliminary requirements for eradicating faults are as follows:
Agree on the specific problem definitions.
Be sure that everyone involved is able to visually inspect the fault, and the operation that produced it. If this is not feasible, provide everyone involved with a photograph of the fault that allows it to be studied for size, shape, and other criteria.
Verify that none of your suppliers made changes to the product, either to the materials or to the process, no matter how slight.
Specify the problem considerations on a concept diagram.
Take the time to look at the process from beginning to end.
Determine if the problem occurs in a specific area. Trace it back to the last acceptable operation or flow path operation.
Agree to the nature of the fault. Is it due to poor design, poor specifications, part weakness, excessive forces, abuse, mismatches, or malfunction?
Determine if there are any witness marks or clues.
Determine if there is one best or worst clue by pattern, serial, mold, machine, operator, shift, day, line, location, mixture, method, and so on.
If the fault can be reproduced, try to replicate it.
Decide if the fault is due to inadequate strength or excess energy.
Capture at least five good and five bad samples for comparison.
Generate the visual clues and analyze the data that you find.
Ensure that only approved material and process changes have been made.
Assign advocates to manage and guide the new system.
If your supplier has more than one instance of the same malfunction, have them certify the product that they send you.
When all else is ineffective, revisit the scene of the crime.
If you follow these methods, your mind’s eye will quickly learn to absorb and analyze clues to the solution. Good luck!