HOW TO SOLVE PRODUCTION PROBLEMS
STEP 1: ISOLATE THE PROBLEM
1. State the Problem 2. Prove the Problem 3. Explore the Cause 4. Draw Conclusion Is it Mechanical, pertaining to things and places? Is it People who: - Don’t know, - Can’t do, - Don’t care, - Won’t do? Statistical data of trouble in production, performance, attitude. Is it Methods, Layout, Tools, Equipment, Materials, Design, Hazards? Is it Wrong assignment? Faulty instructions? Personality situation? Is it MECHANICAL? PEOPLE? or BOTH

STEP 2: PREPARE FOR SOLUTION
MECHANICAL? Methods, Layout, Materials, Tools, Equipment, Design Then improve … Method for better way ANALYZE: • Overall situation 1. Flow chart 2. Flow diagram Question overall job • Specific situation 1. Method 2. Method breakdown 3. Layout 4. Work station set-up • QUESTION EACH DETAIL. Using questions starting with: WHY?, WHAT?, WHERE?, WHEN?, WHO?, HOW? PEOPLE? Don’t know? Can’t do? Don’t care? Won’t do? Then improve … Attitude and behavior GET THE FACTS • Review the records. • What rules and plant customs apply? • Talk with individuals, get opinions and feeling. • • • • WEIGH THE FACTS Fit facts together Check for gaps, omissions, contradictions. Consider their bearing upon each other. Check against company practices and policies. MAKE THE DECISION Consider effect upon individual, group, production

Then improve … Knowledge – Productivity - Skill GET READY TO INSTRUCT • Prepare the Workplace. - Get specified tools, material. - Arrange for best efficiency • Prepare Yourself - Breakdown job for instruction. List the important steps. List key points in each step - Plan the instruction. Prepare the Learner - Put him at ease. - State job. Learn his experience. - Interest him in learning - Explain use and care of tools, equipment, safeguards, etc. - Position him for learning

•

STEP 3: CORRECT THE PROBLEM
DEVELOP THE IMPROVED WAY • Eliminate unnecessary details. • Combine where practical. • Rearrange for better sequence • Simplify