We will lose this business if we cannot correct the problem by the end of the year.” 2.Describe the Current Situation We do this by examining data that is readily available.After you have the problem defined, the model leads you through analyzing data you gather about the process, determining the root cause of the problem, and identifying possible solutions to the problem.
After the best solution is implemented, the model leads the team to monitor the impact of its revisions to make sure that the problem is truly solved.
The problem-solving model, introduced below, incorporates an effective set of skills into a step-by-step process.
And it is often a solution that is short-lived or creates numerous other problems within the organization.
The Problem Solving Model provides you a road map to continuous improvement.
The model combines the use of statistical tools, such as control charts and process flow diagrams, with group problem-solving skills, such as brainstorming and consensus decision-making.
The statistical tools help us make data-based decisions at various points throughout the model.In the case of our hardmask example, we would run test batches to make sure that we have the correct solution in place.Measurements should also be taken on a scheduled basis to continue to confirm that the solution is still valid, making updates if and when needed.This could mean updating specifications, writing new training materials, updating training packages or updating the FMEA.In the case of our hardmask example, we would need to create specifications and appropriate testing methods that will alert us that a batch of raw material is bad before we use it. Monitor for Success After the solution has been implemented, test data can then be created to find which solutions offer the best improvements.Then, when problems do occur, we know exactly what steps to take to help ensure that our solution really will “make it go away.” While there are different variations to an SPS (, etc.), they all follow the same basic steps. Define the Problem It is important to write a problem statement that is easily understood and is stated purely in terms of measurable or observable symptoms.At this point, there should be no mention of suspected causes or possible solutions. A good problem statement might look something like this: “High (greater than 8 ppb) trace metals in one of our hardmask products are causing unacceptably high defect counts with our most important customer.Before you can solve the problem, you must truly understand what it is.This means brainstorming about the process, using a Pareto Diagram to prioritize potential obstacles and creating a process flow diagram of what is currently going on.c) When everyone believes that there is a problem to solve.The first step in the model is to define the problem; it does not matter if it is late shipments, stock outs, computer downtime, typos, lost messages, or an agreed upon "red bead" that everyone keeps running into.