PROBLEM solving

9 Apr 2018
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Problem solving procedure
PROBLEM
Identification(5W1H)
3 Actuals(place, good, reality), Data,
Facts finding Procedure

Probing into 5 Why, 4M+E

the Cause

Countermeasures

Documentation SOP, Instruction, Indication

Education & Training 2

１．Facts finding
・Identification of Defect
+describe the details of occurring problem based on 5W1H
What kind?, When?, Where?, Who?, How?, How many?
+External Outflow
+Management Flow
＊If necessary, try to investigate more.
・Information about production of the concerned lot
+Order flow history:
Spec details, P.O. flow, PIC etc. based on 5W1H
+Production history：
Milling Process :From what time did this lot start to produce, and what time did it
finish to produce? ( Date should be described "day/month" and "hrs./min")
Hanging：same
Dryer：same
Packing：same
+Changing history in each process of the concerned lot
Raw Materials：kinds, blend ratio, area, receiving date
Maintenance history of related process during production :shutdown including
troubles and maintenance
Operator in charge
+Others
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・Inspection status for the concerned lot
+Confirmation of "Quality Process Flow diagram"
Check the inspection status for Bale appearance
(number of inspector, frequency of inspection, record of inspection, the inspectors
during production, qualification record for the concerned inspectors)
+Confirmation of the record of inspections related "Quality Process Flow diagram"

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Key-point of “5 Why”
Improve the process, procedure and system from the view point of our
organization
 Target should be process, procedure and system, not person

 Focus on the concerned behavior, not on the awareness

 Subject of “Why” should be “we” not “person in charge”

3 Actuals (3 Gen doctrine)

 Place the place where trouble occurred such as process line
 Good the product of suffering trouble
 Reality the status of problem

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2. Investigation of the cause
・Based on the above facts, consider the cause through 4M+E(Materials, Method,
Machine, Man, Environment) by 5 why.
・Consider potential causes and make "Fish-born Chart".
・Check each potential cause based on evidence(data, record, hearing and etc.)
・Consider the temporary mechanism of this time defect from the above.
3. Countermeasures
・Based on the above consider the countermeasures for all potential causes,
and make the list of countermeasures.
Check whether each countermeasure apply to prevent recurrence.
・Decide the due date for each countermeasures, and establish the complementing plan.
・Complement the countermeasures in accordance with its plan and check the effect of each
countermeasure by quantitatively.
4. Documentation and Education & Training
・Establish SOP and Instruction
・Set the Indication on each process
5. and Education & Training
・Establish Education Curriculum and Training Manual
・Implementing Education & Training
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