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Importance_of_Problem_Statemen.pdf
Importance of Problem Statement in Solving Industry Problems
Nagappan Annamalai 1,2,a
, Shahrul Kamaruddin 2,b
, Ishak Abdul Azid 2,c
, TS Yeoh
1,d
1 Intel Technology Sdn. Bhd. Phase 3 FTZ. Penang , Malaysia
2 School of Mechanical Engineering, Engineering Campus, Universiti Sains Malaysia, Nibong Tebal,
Penang, Malaysia
Keywords: Problem solving; Problem statement; Manufacturing.
Abstract. Problem statements is a form of natural language used in any problem solvings [17]. A
problem statement is described in terms of scope, structure and its purpose. Analysis in problem
statement is a critical element of a structured problem solving that has not been included in or
explicated by traditional stage models of the process. This paper details out that an analysis stage is
needed to develop the implications of a problem's definition and to direct the selection and pursuit of
solution strategies. This paper also discusses the importance of problem statement and how a new
method of structure is being modeled for an effecient and effective problem solving in industrial
environment. Strategies for future research on problem analysis are discussed
Introduction
Solving problems is a complex process and each of us is better at the skills required at some stages
than others. Why do people fail to find effective solutions? Many reasons can be listed out, as such;
not being methodical, lack of commitment to solve problem, misinterpret problem statement, lack of
knowledge of the techniques and process involved in problem solving, using method inappropriate to
particular problem, and insufficient or inaccurate information to combine analytical thinking.
The term problem solving referring to the mental process that people go through to discover,
analyze and solve problems [20]. This involves all of the steps in the problem process, including the
discovery of the problem, the decision to tackle the issue, understanding the problem, researching the
available options and taking actions to achieve your goals. It is important to first understand the exact
nature of the problem itself (problem statement), before a problem solving occurs [10]. If
understanding of the issue is faulty, then the attempts to resolve it will also be incorrect or flawed.
The problem-solving process is the vehicle for connecting knowledge and performance;
knowledge gains economic value when it is used to solve problems, explore opportunities and make
decisions that improve performance [9]. Problem solving is arguably a primary vehicle for learning in
organizations; individuals may develop a better understanding of their environment by recognizing,
exploring and resolving problems and opportunities. Problem solving may help integrate the diverse
thinking in this area [6].
The concept of problem (problem statement), problem solving method and the application of
problem solving method to a problem are given precise formulations, based on problem type. These
formulation are argued to agree with intuitive understanding of these ideas (mental process), thereby
formalizing them [16].
There are a number of different mental processes at work during problem-solving [10]. The
problem solving process is a cycle [3, 7, 14] that requires; (1) perceptually recognizing a problem, (2)
considering relevant information that applies to the current problem, (3) identify different aspects of
the problem and lastly decribe the problem. The first condition of problem solving is problem
statement and the main concernunder this preatext is the problem analysis.
Problem analysis is a critical element of problem solving that has not been included in or
explicated by traditional stage of problem solving models. An analysis stage is needed to develop the
implications of a problem's definition and to direct the selection and pursuit of solution strategies.
Applied Mechanics and Materials Vol. 421 (2013) pp 857-863 Online available since 2013/Sep/11 at www.scientific.net © (2013) Trans Tech Publications, Switzerland doi:10.4028/www.scientific.net/AMM.421.857
All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of TTP, www.ttp.net. (ID: 165.215.209.15, ProQuest-15/10/13,16:45:37)
Problem analysis is a required key activity for defining a problem statement clearly. The paper
explains and applies a different model of What-Why analysis which generates a richer understanding
and broader set of solution alternatives. Strategies for future research on problem analysis are
discussed.
Problem-Solving Strategies Through Analyzed Problem Statement
A problem statement is a concise description of the issues that need to be addressed by a problem
solving team and should be presented to them (or created by them) before they try to solve the
problem. When bringing together a team to achieve a particular purpose provide them with a problem
statement [19]. The primary purpose of a problem statement is to focus the attention of the problem
solving team. However, if the focus of the problem is too narrow or the scope of the solution is too
limited, the creativity and innovation of the solution can be stifling [15].
A research-worthy problem statement is the description of an active challenge (i.e. problem) faced
by researchers and/or practitioners that does not have adequate solutions available including the
argumentation for its viability based on solid peer-reviewed sources as well as theoretical foundation.
The research-worthy problem statement should address all six questions: what, how, where, when,
why, and who. On the other hand, a statement of the problem is one or two sentences claim that
outlines the problem that the study addresses.
Problem solving strategies or method is the key for solving a problem. The important conundrum
is to understand the problem statement, and the goal to be achieved. The theoretical basis for this
study is research on problem-solving derived from Newell and Simon’s [12]. It focuses on the
conceptualization process that employed for solving problems. In Newell and Simon’s theory,
problems are conceptualized as occurring in a problem space. The problem space (figure 1) contains
three elements: a problem state, which is the information the problem solver, knows about the
problem; a goal state, which constitutes the solution to the problem; and a search space, which
consists of all the strategies that may be employed to solve the problem.
Most problem-solving research has concentrated on what can be described as simple or
well-defined problems. Such problems can be described clearly in terms of the nature of the problem,
what constitutes an acceptable solution to the problem and the various strategies that can be used to
achieve an acceptable solution. It is often the case, however, that complex, ill-defined problems are
complex precisely because it is difficult to define each of the elements of the problem space. With
complex, ill-defined problems it is often not possible to clearly delineate the problem state
Figure 1: Initial state of Problem solving
When solving problems, people employ two types of strategies to navigate the problem space. The
first are algorithms, which are defined as strategies that guarantee a result, with a mathematical
formula being an example of an algorithm. Algorithms tend to be useful for problems where it is
possible to identify all features of the problem space clearly. The second type of strategy is called
heuristics, which are defined as strategies that improve the chances of solving a problem, but cannot
guarantee a solution. Complex problems are often complex precisely because, it is not possible to
identify the characteristics of the problem. Complex problems are most often solved using heuristics
[12].
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Figure 2: Problem Solving with a chain of intermediate states
A number of heuristics has been identified in the literature. There are two general types, referred to
as forward reasoning and backward reasoning [1]. Forward reasoning strategies involve the
problem-solver making a smooth traversal from problem state to goal state (figure 2). Forward
reasoning is often regarded as a strategy used by people knowledgeable in the topic or domain of the
problem and able to choose each step without checking on progress. Backward reasoning involves
trying out strategies and monitoring whether they have moved the problem closer to the goal. Trial
and error is a common backward reasoning strategy employed by people who do not have extensive
experience or knowledge of a problem domain. With problems that require new and creative solutions,
a strategy called problem finding [5] has been identified as an important ingredient of successful
problem solving. Problem finding has been defined as exploring the problem extensively before
attempting a solution and being prepared to change direction when necessary during problem solving
[8]
Figure 3: Problem Solving with a Heuristic pattern
An optimization problem consists of searching the best solution, according to a given criterion,
among a set of feasible solutions [2]. Optimization algorithms are general step-by-step procedures for
solving optimization problems. In other words an optimization algorithm is said to solve a problem if
it can be applied to any instance of that problem to produce a feasible solution. Optimization
algorithms can be exact if they find the optimal solution or heuristic if they find a good solution not
necessarily the optimal one. Heuristics are particularly useful to solve complex problems (Figure 3).
Problem solving is arguably a primary vehicle for learning in organizations; individuals may
develop a better understanding of their environment by recognizing, exploring and resolving
problems and opportunities [9]. The better the clarity around what it is the team is attempting to fix,
the more efficient they'll be in solving the problem, the solution will better 'fix' the issues, and the
team can get back to executing the business versus fixing it. Problem solving strategy starts with
problem definition as stage 1. Problem definition, a stage where the problem statement is reviewed to
have a better understanding of the issue. As mentioned by Kettering (1947) the head of research for
General Motors “a problem well stated is a problem half solved”. Performing What & Why Analysis
Model (Figure 4) will give clear amplification to the importance of solving the problem. Hence
determined the reason behind the cause of stopping the team to solve the problem intially. The fact is,
generally from the observations; the grounds of this circumstances happening is eventually reflected
from the distance between the problem statement and the segmentation. It is often not been bridged
correctly that end- up focusing on inaccurate issues thus resulting into providing non-optimal
solutions.
Applied Mechanics and Materials Vol. 421 859
Figure 4: Why-What analysis model
The team needs to identify the broader problem space by understanding why do they want to solve
the problem, and similarly the team need to understand the narrower problem space by understanding
what is stopping them to solve the problem. By doing this, it will detail out the actual problem
statement and clarifies the connection between broader and narrower problem space. To evaluate the
effectiveness of the proposed What-What analaysis model an industrial case study is used.
Industrial Case Study Of What – Why Analysis Model
In this section it will detailed out on the problem statement by espousing the What - Why Analysis
model through a validation process using case study. Case study research is one of the most powerful
research methods in operational management, particularly in development of new methodology [18].
A manufacturing case study has been identified and presented to show the What-Why analysis model
being adopted for resolving critical issues within a month time frame. The key problem of the case
are two folds; first relating to quality problem faced by a double unit stacked and second is on the high
equipment down time involving a unit drop in a modular station.
A class test (tester used for testing an integrated circuit during the assembly process) that consists
of 3 sub-modules; tester, handler and TIU (test interface unit) will be the equipment choosen for the
validation of What-Why analysis model. The handler module (known as Rxx), which is a mechanical
interface unit which performs PnP (pick and place) of units among 3 sub class test modules. In the
past, a few double stack quality incidents occurred (impacting >2000 units with substrate damage and
fillet crack which impacted to high cost expenditure). To alleviate the risk, the company has put a
quick solution through a manual screening of test summaries to prevent the problems occuring.
However, the solution adopted is unfeasible as it requires intensive resources that eventually
increased the cycle time, and also flagged many false failures. This has triggered the management to
identify a more foolproof solution for this problem. In order to solve the problems, the issue has been
analyzed through 2 method; (1) the usual way which is state the problem and finding the goal that
requires to be pursue. Base on this the problem statement would be double stack on Rxx handler and
how to eliminate double stack, and (2) What-Why analysis model as a fundamental and foundation
base for the problem analysis.
860 Information Technology for Manufacturing Systems IV
Figure 5: Double stack what - why analysis
In reference to the problem of the mentioned case study and referring to Figure 5, it is clear that the
importance of the problem is to avoid any excursion that has the potential to occur. This is due to the
reject been allowed to escape to the customer. The rationale of the problem not being solved properly
is because there is no full proof system been put in place to detect and stop the system from continuing
inducing the rejects. The research has detailed out [11] a full proof solution space with structured
problem solving model known as evolved theory of inventive problem solving(ETRIZ).
A second case study was related to mechanical part of the equipment which induce high equipment
down time involving a unit drop in a modular station. The issue creates unnecessary high equipment
downtime, where fall as high pareto %. This issue potentially induce those drop device reject escape
to customer if the process is not followed accordingly. This problem has been a pain in the neck since
start up, and it has been an unknown root cause for almost 3 years. Standard way of defining the
problem statement would be to eliminate or reduce the CNT drop unit. The problem came to an end by
coaching the technician and engineers with the foundation stage of What-Why analysis model follow
by a structured problem solving method. Performing the analysis (Figure 6) elaborates the
importance of solving the problem, and also what is stopping the team to solve it.
Figure 6: Drop unit what-why analysis
Applied Mechanics and Materials Vol. 421 861
The CNT drop device is important to be resolved as it induce high fall out of the issue and
potentially leads to escapee and lead to excursion alarm to factory. The challange to solve this issue
was due to unknown root cause, where the engineers and technicians has been containing the issue by
changing the unit pick suction cup, which leads to high spare part expenses. The issue was then
resolved starting with What-Why Analysis model, with clear understand on the issue, which also
reduced the duration of solution finding thru a structed problem solving methodology.
Discussion
Rapid problem solving is a key distinguishing feature between organization which excel and those
which struggle. Problem solving requires not only skilled individuals, but need to understand the
problem statement to tackle complex problem. Industries utilize many types of problem solving
methodologies and most of the time the usage of methodology is being neglected either due to
ineffective or too complex. Such situation leads to user confusion and not able to devote their time
successfully on any of the methodologies particularly in relating to manufacturing issues. The paper
describes the important of problem statement in problem solving strategies and how it has been
evolved in fundamental foundation stage of problem definition thru What-Why analysis model which
enhance the usage of the methodology to solve the manufacturing issues.
Problem statement is the fundamental structure that need to be clearly decribed, prior to moving to
the subsequent steps of problem characterization and segmentation [11]. Most of the time problems
are being tackled and resolved in a quick manner, where it is eventually containing the issue, instead
of identifying the actual root cause and resolve the issue/problem for good. This can lead to repeated
issue occurence! What do we want? A strong fundamental understanding of the problem statement
which is known as foundation of a problem. This is required in industries mainly to avoid any
repeated breakdown occurrences. The paper describes a sucessful research and two case studies of
enabling clear problem statement thru introducing What-Why analysis model vs the standard way of
defining the problem statement without a depth understanding.
A full understanding of What-Why Analysis model requires substantial investment in time and
resources, due to its extensive scope and evolution. The key part of the evolution referred to, is the
difficulty in choosing the right tools from those that are available in the market [4]. Applying the
wrong set of tools often results in a waste of effort [13].
Conclusion
Problem solving methodologies appears to be a lack in problem statement part and problem
characterization, that requires substantial effort and commitment to understand and lacks an accepted
standard for its application. The benefit of the What-Why analysis model and its ability to yield
innovative ideas and solution remain prominent and appear widely accepted thru a combination of
structured problem solving methodology.
The paper describes the research methodology and explains the research activities of What-Why
analysis model development. Then, the model validation and case study through its concept has been
presented. The real life case study has demonstrated its capability and accuracy of identifying actual
root cause and providing solution for solving manufacturing problem in industries. Organizations
interested in pushing the boundaries of innovation and remaining competitive should consider this
What-Why analysis approach if they have the means and patience to understand it and embed it in
their innovation strategy and processes.
In summary, What-Why analysis model promises strengthening the problem statement which
enables a good innovation ideas and solutions, which many organizations see as a source of
competitive advantage.
862 Information Technology for Manufacturing Systems IV
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