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ME290-Chapter6ProblemSolvingRootCauseAnalysisRiskManagement-Lecture1.pdf

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ME290

Global Engineering Professional Seminar

Problem Solving, Root Cause Analysis, Risk

Management

Lecture-1

ABET* requirement: General Criterion 3. Student Outcomes

The program must have documented student outcomes that prepare graduates to attain the program educational objectives:

 1. an ability to identify, formulate, and solve complex engineering problems

by applying principles of engineering, science, and mathematics

 2. an ability to apply engineering design to produce solutions that meet

specified needs with consideration of public health, safety, and welfare, as

well as global, cultural, social, environmental, and economic factors

Problem Solving, Root Cause Analysis, Risk Management

*ABET (Accreditation Board for Engineering and Technology, Inc.) is an organization that accredits post-secondary education programs.

Engineers: Problem Solvers

Engineers are creative problem-solvers

Typical Problems in Engineering

Problem: Aircraft crashed Reason/Solution?

Problem: Car Engine Intake Cracking

Reason/ Solution?

Typical Problems

Any Tools/Techniques to Help?

Problem: Welding Defects in production Reason/Solution?

Problem: Bolt Corrosion and failure Reason/Solution?

Typical Problems

Any Tools/Techniques to Help?

Problem/Need: Improve Low Metal Cutting Productivity Reason/Solution?

General Problem Solving Strategy

1. Define/Identify the Problem

2. Determine the Root Cause(s) of the Problem

3. Develop Alternative Solutions

4. Select a Solution

5. Implement the Solution

6. Evaluate the Outcome

•Step 1: (Hypothesis) “Plan” A. Identify problem B. Investigate root cause(s) C. Select appropriate solutions

•Step 2: (Try) “Do” • Implement solutions

•Step 3: (Reflect) “Check” • Study the Results

•Step 4: (Adjust/) “Act”

• Standardize and Plan Continuous Improvement

Plan-Do-Check-Act (PDCA) Tool

Step 1

(A)

Problem

Identification

Step 1

(B)

Cause

Investigation

Step 1

(C)

Select

Countermeasures

Step 2

Countermeasure

Implementation

Step 3

Study the

Results

Step 4

Standardize and

Plan Continuous

Improvement

Plan

Check

Act

Step 1: Define/Identify the Problem

• What is the problem? • Status, background and symptoms (measurements, trials/tests,

failure/incident reports, user complaints etc.)? • Who/What/How does it affect / does not affect? • When/Where is it a problem / is not a problem? • If this is an old problem, what's wrong with the previous solution? • Is this the real problem, or merely a symptom of a larger one?

Step 2: Determine the Root Cause(s) of the Problem

Root Cause Analysis is a technique for identifying the most basic factors/reasons underlying in a problem.

Step 2: Determine the Root Cause(s)

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Step 2: Determine the Root Cause(s)

EFFECT

“M’s” Model

MAN METHOD

MATERIALS MACHINERY

OTHER

(Manpower, Methods, Material, Machines, Measurement, Mother-Nature/Environment, Management, etc.)

Step 2: Determine the Root Cause(s)

The Cause & Effect, or fishbone diagram, was first used by Dr. Kaoru Ishikawa of the University of Tokyo in 1943 - hence its frequent reference as a "Ishikawa Diagram". This diagram is used to identify all of the contributing root causes likely to be causing a problem. This methodology can be used on any type of problem, and can be tailored by the user to fit the circumstances. Use of this tool has several benefits to process improvement teams: • Straightforward and easy to learn visual tool. • Involves the workforce in problem resolution - preparation of the fishbone

diagram provides an education to the whole team. • Organizes discussion to stay focused on the current issues. • Promotes "System Thinking" through visual linkages. • Prioritizes further analysis and corrective actions.

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Step 2: Determine the Root Cause(s)

MAN/WOMAN METHOD

MATERIALS MACHINERY

OTHER

Inserted CD Wrong

Instructions are Wrong

Not Enough

Free Memory

Inadequate System

Graphics Card Incompatible

Hard Disk Crashed

Not Following

Instructions

Cannot Answer

installation Questions

Brain Fade

CD Missing

Wrong Type CD Bad CD

Power Interruption

Aircraft Crashed

Man Machine Methods

Mother Nature

Materials Measurement

Gauge

Puller

Maintenance

Cracking

Rain

Training

Driving

Tow Bar

corrosion

Wind

Speed

Step 2: Determine the Root Cause(s)

Dissatisfied worker

Machines Management

Mother Nature Men

Training

Salary

Obsolete

Dangerous

Unfaithful

Incapable

To hot

Terrible cold

Step 3: Develop Alternative Solutions

Step 4: Select a Solution

• Which solution is most feasible? • Which solution is favored by those who will

implement and use it? • Can be implemented within an acceptable

timeframe? • Is cost effective, reliable and realistic? • Will make resource usage more effective? • Can adapt to conditions as they evolve and

change? • Its risks are manageable? • Will benefit the organization?

Step 5: Implement the Solution

Step 6: Evaluate the Outcome

• If the outcome/results is satisfactory: Congratulations • If the outcome/results is not satisfactory or needs

improvement: Go back to Step 1 and Review all previous Steps

End of “Problem Solving, Root Cause Analysis,

Risk Management”

Lecture-1