Trouble Shooting & Process Improvement

Introduction

This training program provides participant with the concept of problem solving and trouble shooting. Implementing solutions without getting to the true root cause is a waste of money, time and resources. Traditional approach begin with limited info, many actions and lacking focus. Our approach focus on finding the true root cause before proceeding with actions.

Course Objectives

• Apply 7 steps of trouble shooting
• Understand basic concept of Lean
• Recognize the 7 wastes at the workplace for process improvement
• Able to adopt relevant lean practices/ tools to identify opportunities for operational excellence at workplace

Key Content

Module 1: Introduction to Six Sigma

• DMAIC concept
• Define, measure, analyze, improve, control

Module 2: Waste Identification

• 7 deadly waste - TIMWOOD
• Transportation
• Inventory
• Motion
• Waiting
• Over processing
• Over production
• Defects
• Value added/ non value added

Module 3: Tools & Techniques

• 7 QC tools
• Check Sheet
• Pareto Chart
• Fishbone Diagram
• Scatter Diagram
• Histogram
• Control Chart
• Graph
• Brainstorming
• 5 Whys
• 3MU elimination approach
• 5W1H

Module 4: 7 Steps for Trouble Shooting

• Problem Definition
• Background
• Specify problem
• Ideal state - Current state = problem
• Goal setting
• Quantify the problem - what, where, when
• Set goals (stretch)
• Timeline
• Progress update
• Identify points of cause
• Identify root cause
• Identiy solutions to address root cause
• Executes
• Confirmed if goals achieve
• Activity plan
• Root cause analysis
• Generate and implement countermeasures and corrective actions
• Review results
• Standardized and share learnings

Module 5: What is Lean?

• What and why?
• Difference between lean and six sigma
• Lean concept in manufacturing/ service and the benefits

Module 6: Building Lean Culture

• Buy in from management and staff
• Link Lean initiatives to departmental goals
• Measure effectiveness of Lean initiatives