Toyota - Apuntes Chapter 9 PDF

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Resumen del video de Toyota's 8 practical problem solving methodology...

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GROUP 7

TOYOTA’S 8 STEP PRACTICAL PROBLEM SOLVING METHODOLOGY What is a problem? 1. Definitions: a. A deviation from the standard. b. A gap between actual and desired conditions. c. An unfulfilled customer needs. 2. Different types: a. When the standard is not achieved. b. When the standard is achieved, but a higher standard is now required. c. When the performance to the standard varies. It’s not constantly achieved.

Why practical problem solving? 1. Enables organizations to have a common understanding and definition of what a problem is, what creates a fast and urgent initial response. 2. Removes time lost in debate so that it can be used in problem solving. 3. Ensures that problems don’t reoccur.

PDCA: Plan, Do, Check and Act. Usually organizations spend very little time in planning but that’s an efficiency mistake at the end.

Problem solving approaches: 1. Just do it: Used for simple problems, that don’t need much time and resources. Fix the problem and move on. 2. 8 Disciplines: Used for engineering problems. a. Define the problem. b. Build a team. c. Containment action. d. Determine the root cause. e. Verify the root cause. f. Corrective action. g. Prevention. h. Congratulate the team.

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3. 6 Sigma: Used to fix problems associated with variations and defects. DMAIC. a. Define b. Measure c. Analyze d. Improve e. Control

8 Step problem solving: 1. Based in Toyota’s business practice as a detailed explanation of how the PDCA cycle works. 2. Steps: a. Clarify the problem: Describe the current situation while watching with our eyes and getting the facts. It’s important to know if we’ve contained the problem despite if it’s with a temporary solution. b. Break down the problem: More specific and smaller problems. Watch the problem with our eyes. Study the inputs and the outputs of the process. c. Set a target we will achieve: The target must but a challenge but also must limit scope. It’s a must do target. Must take us one step toward the ideal. d. Analyzing the root cause: Go and watch with your own eyes. Find points of cause. e. Develop countermeasures. f. See countermeasures through: Ideas of many people are important. Communicate the status. Use the PDCA cycle. “Don’t give up.” g. Evaluate both results and process: “Was this the effect of the countermeasures or just luck?” h. Standardize success and learn from failures: Copy and expand good ideas to

other areas. Face and learn from unresolved issues....