Learn Toyota's 8 Step Practical Problem Solving Methodology

Summary

This Gemba Academy course introduces practical problem-solving, emphasizing the PDCA cycle and the eight-step process. It highlights the importance of a common understanding of problems, efficient root cause analysis, and mistake-proofing to prevent reoccurrence. The course also compares this approach with other methodologies like Six Sigma DMAIC.

Takeaways

• 📚 The Gemba Academy Practical Problem Solving course aims to teach what a problem is and how companies like Toyota use practical problem solving to improve their operations.
• 🔍 A problem can be defined as a deviation from the standard, a gap between actual and desired conditions, or an unfulfilled customer need.
• 📊 Problems are categorized into three types: not meeting the standard, needing a higher standard, and inconsistent performance to the standard.
• 🤝 Practical problem solving fosters a common understanding of what a problem is, leading to a faster initial response and less time wasted in debates.
• 🛠 The PDCA Cycle (Plan, Do, Check, Act) is a fundamental concept in problem solving, with emphasis on the planning phase to avoid hasty decisions.
• 🚀 Practical problem solving helps organizations focus on solving problems efficiently and effectively, preventing reoccurrence through root cause analysis and mistake proofing.
• 🛑 The 'Just Do It' approach is suitable for small problems that can be quickly fixed without extensive resources.
• 🔧 Ford's Eight Disciplines problem-solving process is distinct from the eight steps of practical problem solving, though they share similarities.
• 📈 Six Sigma's DMAIC methodology (Define, Measure, Analyze, Improve, Control) is used to tackle problems related to variation and defects.
• 📝 The Eight Step Practical Problem Solving Process is closely based on Toyota's business practices and includes steps like clarifying the problem, setting targets, and analyzing root causes.
• 🔄 The final steps of the process involve following up, evaluating results, standardizing success, and setting new targets for continuous improvement.

Q & A

What is the primary goal of the Gemba Academy Practical Problem Solving course?

The primary goal of the course is to teach participants the eight steps to practical problem solving, enabling them to understand what a problem is and how companies like Toyota use this approach to improve their way of working.

How is a problem defined in the context of this course?

A problem is defined as any deviation from the standard, a gap between actual and desired conditions, or an unfulfilled customer need.

What are the three types of problems mentioned in the script?

The three types of problems are: 1) When the standard is not achieved, 2) When the standard is achieved but a higher standard is now required, and 3) When performance to the standard varies inconsistently.

Why is practical problem solving considered a powerful approach according to the script?

Practical problem solving is powerful because it enables a common understanding and definition of what a problem is, removes time lost in debate, and through planning and root cause analysis, ensures problems don't reoccur.

What does the PDCA Cycle stand for and what is its significance in problem solving?

The PDCA Cycle stands for Plan, Do, Check, and Act. It is significant in problem solving as it provides a structured approach to tackle issues systematically and ensure continuous improvement.

What is the importance of the 'plan' phase in the PDCA Cycle?

The 'plan' phase is crucial because a failure to plan properly often results in longer times to resolve the problem. Proper planning helps in solving problems faster and more efficiently.

What is the difference between the 8D problem solving process and the eight steps of practical problem solving?

While both share some similarities, the 8D problem solving process is specific to engineering problems and was adopted by Ford Motor Company, whereas the eight steps of practical problem solving are a more general approach used by companies like Toyota.

What is the first step in the Eight Step Practical Problem Solving Process?

The first step is 'Clarifying the Problem', which involves clearly describing the current situation and understanding the facts by going to see with one's own eyes.

What does the term 'genchi genbutsu' mean and how is it used in the problem solving process?

Genchi genbutsu is a Japanese term meaning 'go and see'. It is used in the problem solving process to emphasize the importance of personally observing the problem situation without prejudice, rather than relying solely on reports or second-hand information.

What is the purpose of the 'follow up' phase in the practical problem solving process?

The 'follow up' phase, or step seven, is meant to evaluate both the results and the process. It helps to determine whether the countermeasures were effective or if success was due to luck, ensuring continuous learning and improvement.

What does the final step of the Practical Problem Solving Method focus on?

The final step focuses on standardizing success using 'Yokotin', which involves copying and expanding good kaizen ideas to other areas, identifying unresolved issues, and setting the next targets for improvements.