Logo Name of Institution

Apply problem solving tools

and techniques
NTQF for Level IV

UnitofCompetence: Apply problem solving tools

and techniques
ModuleTitle Applying problem solving tools
and techniques
LGCod 4 M04 LO2-07
e: 4 TTLM 0715V1
TTLMC
ode:

LO 2: Grasp current Status and Set Goal

(Fact analysis)
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 Instruction Sheet Learning Guide #2

This learning guide is developed to provide you the necessary information regarding
the following content coverage and topics –
 Methods to grasp the current status of the problem
 Goal setting

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
 Define the extent of problem.
 Set appropriate and achievable goal.

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described in number 3 to13.
3. Read the information written in the “Information Sheets 1”. Try to understand what
are being discussed. Ask you trainer for assistance if you have hard time
understanding them.
4. Accomplish the “Self-check 1” in page 7.
5. Ask from your trainer the key to correction (key answers) or you can request your
trainer to correct your work. (You are to get the key answer only after you finished
answering the Self-check 1).
6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However,
if your rating is unsatisfactory, see your trainer for further instructions or go back to
Learning Activity #2.
7. Submit your accomplished Self-check. This will form part of your training portfolio.
8. Read the information written in the “Information Sheet 2”. Try to understand what
are being discussed. Ask you trainer for assistance if you have hard
time understanding them.
9. Accomplish the “Self-check 2” in page 13.
10. Ask from your trainer the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 2).
11. If you earned a satisfactory evaluation proceed to “Operation Sheet 1” in page 15.
However, if your rating is unsatisfactory, see your trainer for further instructions or
go back to Learning Activity #1.
12. Read the “Operation Sheet 1” and try to understand the procedures discussed.

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13. Do the “LAP test” in page 16 (if you are ready). Request your trainer to evaluate your
performance and outputs. Your trainer will give you feedback and the evaluation will
be either satisfactory or unsatisfactory. If unsatisfactory, your trainer shall advice you
on additional work. But if satisfactory you can proceed to Learning Guide #3.

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 Information Sheet-1 Methods to grasp the current status of the problem

1. METHODS TO GRASP THE CURRENT STATUS OF THE PROBLEM

In fact analysis you clarify the impact of the problem (the difference between the
current status and the target status) and use stratification to identify variability. See
Figure 1.

Figure 1 Example of narrowing down themes with a WBA board.

Fig.1 WBA board

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 1.1 Quantify the current status
Problem-solving starts with accurate fact analysis to determine how bad the current
status is.
Identify the problem
Key points
 All of the QC circle members discussed the problem thoroughly, to get to the
essence and to identify what is essentially amiss. Use a process flow chart, the
4Ms, and other means to look at the problem in its broader context.
 Get a systematic understanding of the problem with cause and-effect diagrams,
affinity diagrams, and other tools that enable you to see the whole picture.

Narrow down the facts of the problem

Key points
 Get the facts based on the three actualities (the actual reality of the actual
situation at the actual site).
 Personally conduct an on-site examination of the part, tool, or equipment that
seems to be causing the problem so that you can make an objective statement
of the problem. Investigate and confirm to get all of the facts that you need.
 You need to do more than just look. You need to conduct a close, hands-on
examination of the problem.

Facts should be expressed quantitatively

Key points
 Have the QC circle members discuss how to quantify the facts, including using
sample surveys, doing experiments and tests, and completing questionnaires.
 All of the circle members think about how the relevant data can be expressed
numerically.

Collect data and prepare graphs

Work quantitatively and objectively
Key points
 Collect the necessary data in sufficient quantity, knowing clearly what is to be
measured so that it is easy to stratify the data.
 Remember that data are most current immediately upon collection and start
getting stale immediately.
 Do not collect just the convenient data. Be sure to get everything you need,
including the data that make your job harder by forcing you to get at the
underlying causes.
 It is imperative that the QC circle use objective

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 Figure 02 using a histogram for fact analysis

Examine and stratify data on the current situation from a number of

perspectives.
Key points
 Do not confuse data that show causes with data that show results.
 Stratify data from various angles, such as by time, location, operator,
symptom, product, machine type, production method, and more. See
Figures 19 and 20.
 Continue the stratification process until there are substantial
differences among the stratification groups.

1.2 Identify variability

Identify variability by using the results of the stratification.
Select problems whose solution will make a major contribution to better results.
Key points
 Continue to stratify until variance is identified.
 If you cannot get enough examples, one effective way to find
differences is to compare good products and defective products.
 Do not concentrate only on mean values to identify problems. Also
pay attention to variability. See Figure 02.
 Select high-impact problems.

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 Self-Check 1 Written Test

Directions: Answer the following question.

1) How to identify and narrow down them current status of the problems? (5 points)
2) What are the most relevant QC tools to express problems in numerically? (5
points)
3) How to identify variability of problems? (5 points)
4) Select workplace and apply methods to grasp the current status of the problem.
(10 points)

Note: Satisfactory rating - 20 points Unsatisfactory - below 20 points

You can ask you teacher for the copy of the correct answers.

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 Answer Sheet
Score =
Rating:

Name: Date:

Short Answer Questions.

1.

2.

3.

4.

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Information Sheet 2 Set goal

2. SET THE TARGET

A target is critical, because it serves as a yardstick against which to measure
the results of the corrective action in specific terms and makes your activities
more challenging and more rewarding.

Figure 03.using Pareto charts for fact analysis

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Figure 04 Using work element studies for fact analysis

2.1 Clarify the three elements of your target

Key points
 Determine the three elements of the target:
1. What (target item) should be fixed?
2. To what extent (target value) it should be fixed, and
3. By when (target date) it should be fixed.
 Quantify the target value so it is expressed numerically.
 Numeric values help clarify and quantify your accomplishment.

2.2 The target must be high enough to motivate people

Key points
 State the need for the target and its appropriateness. The target
should not be too easy. It is better to have a challenging target to
motivate people to exert themselves. A target that is too easy may
well be meaningless, both for the company and for the individuals
involved.

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  State clearly what you expect to achieve.

Figure 05 expressing the target numerically

Figure 06 Using work element studies for fact analysis

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 Figure 07 expressing the target numerically

2.3 Use a substitute characteristic (value) when necessary

If the target is not directly quantifiable, use a substitute characteristic that can be
quantified.
Key points
 Organize the factors in a cause-and-effect diagram to help you
choose a suitable substitute characteristic.
 Select the substitute characteristic with the highest contribution rate
(the most impact on the effect).
This is usually the item on the extreme left in your Pareto chart.

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 Self-Check 2 Written Test

Directions: Answer the following question.

1) What are three elements of targets? (3 points)

2) Why those elements are consider high motivation of people? (5 points)
3) Select methods to set goal for the selected problem. (7 points)

Note: Satisfactory rating - 10 points Unsatisfactory - below 10 points

You can ask you teacher for the copy of the correct answers.

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 Answer Sheet
Score =
Rating:

Name: Date:

Short Answer Questions

1.

2.

3.

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Operation sheet-1 Methods to grasp the current status of the problem

3. OPERATION SHEET FOR METHODS TO GRASP THE CURRENT STATUS OF

THE PROBLEM

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 LAP Test Practical Demonstration

4. LAP TEST
Name: Date:
Time started: Time finished:

Instructions: Given necessary templates, workshop, tools and materials you

are required to perform the following tasks within 2 hours.

Task 1: Prepare tools and equipment.

Task 2: Identify the current status of the problem.-

 Brainstorming
 Process flow
 Cause analysis
Task 3: Express fact analysis in terms of numerically.

 Sample survey
 Experiments and tests
 Questionnaires
Task 4: Collect data and graph them.

 Histogram
 Different graphs
 Pareto diagrams
 Stratification
Task 5: Determine variability:

 Histogram
 Pareto diagrams
 Stratification
If the variability is unclear, redo the stratification.

Task 6: Set a target:

 Include the target elements: 5W1H
 Make sure the target is appropriate.
 Express the target numerically.

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 5. LIST OF REFERENCE MATERIALS

No Name books Author Remarks

1 QC CIRCLES (LEADERS’S GUIDEBOOK FOR LEVEL JUSE press.
IDENTIFICATION LTD
2 KAIZEN (THE KEY TO JAPAN’S COMPETITIVE MAASAKI
SUCCESS) EMAI
3 QC PRACTICES TAKANORI
YONEYAMA
4 QC STORY LINE TADASHI
SUGIURA
5 FUNDAMENTALS OF QC CIRCLES JUSE Press,
LTD.
6 KAIZEN NATIONAL MOVEMENT JICA
7 KAIZEN BEST PRACTICES OF QC CIRCLES JICA
8 KAIZEN MANUAL (APP) EKI
9 KAIZEN MANUAL (THEORY) EKI
10 HOW OPERATE QC CIRCLES JUSE
11 BASICS OF IE
12 HAND BOOK FOR TQM AND QCC (VOL I & II) 1999
13 SAFETY MANUAL AND GUIDE

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