|
07/20/2011 02:45 PM
|
|
|
Hi All,
I am interested to learn if anyone is using Toyota's 8 Step Problem Solving Method. From my internet research most companies are seem to be using A3 Problem Solving. My company is interested in learning more about the 8 Steps but I can't seem to find much on the topic. There is a little mentioned in The Toyota Way, and The Toyota Way Fieldbook, but not in any great detail.
Does anyone have a PPT or PDF that they can share? or maybe a link with some useful information.
Thanks in advance
Justin
|
|
|
|
|
07/21/2011 04:10 PM
|
|
|
There are a number of books on A3 problem solving out there.
I'd pick up one of the more recent ones, and try to do what it says.
"Managing to Learn" is one.
"Toyota Kata" is really good.
Art Smalley's book "A3 Problem Solving" is another.
You aren't going to get this from a powerpoint presentation.
It is like learning to play the guitar, or learning to swim. You have to practice, and accept that you are going to do it badly at first.
|
|
|
|
|
07/22/2011 10:09 AM
|
|
|
Thanks Mark.
I appreciate your feedback. I agree all those books are great reference materials for A3. You should check out "Getting the Right Things Done" by Pascal Denis, used more for strategic planning.
I am familiar with A3 Thinking,I've been using it for the past 4 years, and by no means a expert. However, my query was about Toyota's 8 Step Problem Solving method. Just wondering if there is anyone out there using it in their organizations and if the have any material that they might be willing to share.
Thanks again for your reply.
Cheers
|
|
|
|
|
07/22/2011 10:09 AM
|
|
|
Hi Justin,
I've not used the 8 Discipline approach myself, but my company is applying it in places. When I check what it means on Wikipedia and in internet content, and chat to colleagues, it strikes me to be very similar to the so-called A3 approach. If you've not done so already, I'd suggest an internet check yourself and I think you'll see what I mean. And I feel, as with most of these approaches... spot a problem and apply it and there should be a lot of learning on the way???
I'd appreciate any thoughts you have arising in return.
Kind regards
Robin
|
|
|
|
|
07/22/2011 10:09 AM
|
|
|
Hi justin,
I don't have a PDF but "The New Lean Pocket guide has a section on problem solving that is a 6 step process and gives a great precis with tips and checklists.
Might be worth a look. If I remember rightly I bought mine on Amazon. It has since been updated I believe, but don't quote me.
also, John Bicheno has a Lean 'tool kit' that might help. I don't have a copy but i'm sure someone out there does who could tell you if it's suitable.
hope this helps,
Tim
|
|
|
|
|
07/22/2011 10:09 AM
|
|
|
As an Addendum to my previous post.
The 6 steps are below. they should be done in order. Standardised across org. Any size problem. Groups/Individuals. May lead to the generation of an A3 if big enough.
1 Describe the problem.
2. Implement temporary containment
3. Analyze and generate possible solution(s) (PLAN)
4. Determine root cause and select solution(s) doing it here stops conclusion jumping.(PLAN)
5. Implement (DO)
6. Verify effectiveness (CHECK- Measure)
my addition -
Adjust perhaps?
Regards,
Tim
|
|
|
|
|
07/22/2011 10:10 AM
|
|
|
There is a very good power point presentation on 8D Problem Solving by Marc. It is good for starters though you need a lot of practice to master the art.
Umang
Mod note: Edited to correct link text
Edited: 07/22/2011 at 10:10 AM by Lean Moderator
|
|
|
|
|
07/22/2011 10:10 AM
|
|
|
Justin,
I have a 8 D format for you if you would like it.
Mod note: Edited to add attachment
Edited: 07/25/2011 at 10:45 AM by Lean Moderator
|
|
|
|
|
07/22/2011 10:10 AM
|
|
|
Justin,
I support the Air Force who uses the 8 step problem solving methodology - my first exposure to it after years of using DMAIC. All the other services use DMAIC. If you have a choice, I strongly recommend going with the DMAIC approach - just cleaner, simpler and more intuitive.
Pat
|
|
|
|
|
07/25/2011 10:31 AM
|
|
|
Justin,
I have my interpretation of the 8 step model on my web page at http://www.signpostconsulting.biz/problem_solving
If this looks like what you are looking for, then send me a message, and I can provide a bit more info.
Regards,
Dave Simpson
|
|
|
|
|
07/25/2011 12:34 PM
|
|
|
Hi All,
thanks for all the responses, it is greatly appreciated.
The 8 Step Problem Solving method, from what I understand, and I am by no means a guru, is also called the Toyota Business Process and it looks like this.
1. Clarify the problem (I guess Grasp the Situation)
2. Breakdown the problem
3. Set Target
4. Analysis the Root Cause
5. Develop Countermeasures
6. See Countermeasures Through
7. Evaluate
8. Standardize
It is different than the 8D that originated from the Big 3 (worked in Auotmotive for a while lol) and also different than DMAIC - which I am very familar with).
I am trying to put together a presentation to share with my Colleagues to help them understand the 8 Steps.
Has anyone used this with any success?
I am interested to learn what I can about this, but I just can't seem to find much detail.
Thanks for all your help.
cheers
|
|
|
|
|
07/29/2011 03:53 PM
|
|
|
Hi Justin,
When I was working at Toyota we learnt their Practical Problem Solving Method and the basic steps were as follows:
1. Clarify the problem.
2. Set the target - i.e. what does success look like.
3. Determine the problem's Point of Cause - not always where it became apparent!
4. Go and observe the process at the Point of Cause to determine the Direct Cause - Fishbone Diagrams can be useful here.
5. Implement a temporary solution to fix the Direct Cause.
6. Identify the underlying Root Cause - The 5 Whys are a good tool to do this (Note a person is never the Root Cause).
7. Determine and implement a solution to the Root Cause.
8 Verify that the solution to the Root Cause is working and that you have achieved your target.
9. Remove the temporary solution to the Direct Cause and verify that the Direct Cause does not reappear - If it does you did not find the right Root Cause!
10. Widely publish the findings and identify other areas of the business that can benefit from your learning.
Since I left Toyota I find the following steps are commonly missed:
3. Determine the problem's Point of Cause - not always where it became apparent!
9. Remove the temporary solution to the Direct Cause and verify that the Direct Cause does not reappear - If it does you did not find the right Root Cause!
10. Widely publish the findings and identify other areas of the business that can benefit from your learning.
|
|
|
|
|
07/29/2011 03:53 PM
|
|
|
Dear Justin,
We are also implementing the 8 Step problem solving process in our company.
Attached is a pdf of a "Quick Tip folding card", I have made this to make it more visual for the employees as well as a presentation on Problem Solving.
The presentation is a summary of what I have found in several other presentations as well as own input, but "tailor made" for our purposes.
Grts, dirk
|
|
|
|
|
07/29/2011 03:53 PM
|
|
|
HI,
Based on a recommendation I saw in this forum, I bought Sobek and Smalley's book "Understanding A3 Thinking - A Critical Component of Toyota's PDCA Management System." Highly recommend it. The first chapter alone is worth buying the book for. This is the background and history behind the concepts to the A3/ 8-step problem solving approach that I have not found anywhere else - at least not in the detail this book provides. It also explains so well the importance of understanding PDCA behind the A3 approach. I am attaching a sample A3/8-step template you may find useful.
Pat
|
|
|
|
|
08/30/2011 01:17 PM
|
|
|
Hi all,
Sorry for not getting back sooner....enjoying summer vacatioin.
All the suggestions, help, and templates are greatly appreciated. This forum is an awesome format for getting guidence and sharing best practices.
Warmest Regards,
Justin
|
|
|
|
|
04/20/2012 11:49 AM
|
|
|
Justin,
My understanding is that A3 is a visual format used to perform the 8 steps to problem solving. (I know call me Mr. Obvious)
You could develop your own format to visually represent the 8 steps.
I believe what is important is that you understand the steps not what format you use.
With that said; it is important to have a standard format/method for problem solving. So whether you call it PDCA, 8D, DMAIC or any other format is should incorporate the steps needed to do good cause analysis, robust solutions and standards to ensure improvements are made.
At times when I am looking for more clarity or examples of processes I visit LEI or www.gembapantarei.com or www.mindtools.com as a references (I am not promoting anyone site, doing is the best method of understanding, experiment)
Billy
Billy
|
|
|
|
|
05/01/2012 10:40 AM
|
|
|
8D is not for problem solving. Step 4 of the 8D is root cause analysis and you can use any method you want to solve the problem.
8D is more of a standard reporting method.
|
|
|
>
Community >
Forums
Send to a Friend
