Reliability Solutions

Problem Solving

One of biggest issues in high volume / low cost electronic manufacture is the ability to manage problems and develop a successful approach to Continual Improvement (CIP).

In order to drive Cost Reduction initiatives and 'Lock-in' improvements a well structured CIP programme is a necessity in today's environment.

Making Continual Improvement a reality requires a strong organised approach to Problem Solving and Problem Management

Reliability Solutions offers a 1.5 day training seminar on Problem Solving

Training Outline

- Basic Introduction to the Ford Motor Company 8D Problem Management Programme and the importance of Strong Problem Management skills

- Measuring the impact of 8D Improvement Projects

Focusing on Key Process / Customer measurements which will define success of Improvements

Individual Process Control Measures
Equipment Up Time
Scrap Level
Customer Return Level
Occurrence of Repeat Customer 8D issues

- Using the modern Problem Mgmt model - D.M.A.I.C (Define, Measure, Analyse, Improve, Control) to manage problems in a high volume environment

Defining the problem and organising the thought process to minimise wasted effort.

Use of Pareto Analysis and Basic Probability statistics
Use of the Problem Facilitator in driving rapid solution
Developing the 'Motivated' team

Measuring the extent of the problem

Flowcharting the process
Creating Cause and Effect diagram to define all possible sources of variation
Identifying the key Process Input / Output variables

Analysis of the problem using Cause and Effect Analysis / Rating

Using the '4-Block' analysis approach to focus on Impact / Implementation analysis
Developing Action Plans from C&E Analysis to ensure efficient communication of Improvement Projects

Making Improvement with a structured approach

Focuses on discovering the key variables that cause the problem
Using Handover Logs efficiently to ensure improvements carried from shift to shift
Remove the old habits of starting to solve the problem before understanding it!
Setting up Continual Improvement Project Charters

Controlling the Processes to prevent problem recurrence

Adopting the 'Lessons-Learned' approach and how to build into standard Audit Procedure within Atmel Process
Setting up 'Quality Champion' role for effective internal auditing of Lessons Learned implementation and ongoing application plus
Ongoing review of Countermeasure effectiveness
Setting up regular review formats
Conformance to standards (via internal audits)

Company Background	Consultancy Experience	Specialist Areas of Consultancy

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Reliability Solutions, 18 Hillside, Houston, Renfrewshire PA6 7NT, Scotland
Tel: 44(0)1505 320352	Fax: 44 (0)1505-382769	Mobile: 07967 144097	Email: martinshaw1@compuserve.com