Day 1 AM

·  What is Problem Solving?

·  Why use a structured process?

·  PDCA

·   Introduction to the 8D Model:

Ø   D0 Prepare for the process

Ø   D1 Use a team approach

Ø   D2 Describe the problem

Ø   D3 Implement and verify containment activity

Ø   D4 Define root cause

Ø   D5 Develop permanent corrective actions  

Ø   D6 Implement and verify corrective actions

Ø   D7 Prevent recurrence

Ø   D8 Congratulate your team

·    DMAIC and Six Sigma

·    Comparing DMAIC to 8D and PDCA

·    8D Documentation and examples

·    Problem Solving Tool Selection Matrix

Ø    Selecting the right tool for the job

·    D0 Prepare for the Process

Ø   Getting started

Ø   Problem selection

Ø   Pareto charts

·    D1 Use a Team Approach

Ø   Team selection and makeup

Ø Exercise: Form teams, design a check sheet to collect data and perform initial data collection run

Day 1 PM

·  D2 Describe the Problem

Ø   The importance of collecting and interpreting data

Ø   Problem statements and operational definitions

Ø   Flow charts

Ø  Exercise: Use an IS/IS NOT worksheet to develop problem definition

·  D3 Implement and Verify Containment Activity

Ø   Containment strategies -Thinking outside the box

Ø   Problems with containment

Ø   Exercise: Identify possible containment strategies

·  D4 Define Root Cause

Ø   Root cause analysis methodology

Ø   Structured brainstorming techniques

Ø   Cause and Effect (Fishbone) Diagrams

Ø   Repeated Whys (5 Whys)

Ø   Cause of Occurrence vs. Cause of Escape

Ø  Exercise: Use structured brainstorming methods, and a fishbone diagram to identify and classify possible root causes

Day 2 AM

·   Review of homework and case studies

·   D4 Define Root Cause (continued from day 1)

Ø    Exercise: Design a simple experiment to isolate root cause

Ø    Run Charts

Ø    Exercise: Construct a run chart

·   D5 Develop Permanent Corrective Actions

Ø    Developing an Action Plan

Ø    Error Proofing (Poka Yoke)

Ø    Nominal Group Technique

Ø    Exercise: Use NGT to reach consensus on corrective actions - develop PCAs

·   D6 Implement and Verify Corrective Actions

Ø    Putting the Action Plan into place

Ø    Action Matrix

Ø    Force Field Analysis

Ø    Histograms 

Day 2 PM

Ø    Scatter diagrams

Ø    Exercise: use a scatter diagram

·   D7 Prevent Recurrence

Ø    Identifying recurrence issues

Ø    Leveraging your success for maximum ROI

Ø    Value Stream Mapping (VSM)

Ø    Control Charts and Basics Concepts of SPC

Ø    Process Capability

·   D8 Congratulate Your Team  

·   8D Auditing

·    Summary and Wrap-up