How can entry-level manufacturing workers develop problem-solving skills?

Based on my experience, we need to start right and create the following: 1. The right system: a. Proper Onboarding Process with the right materials and tools. b. Certification Process so they can have an actual hands-on of the process and better understanding of potential failures and how to react on them once it occur. c. Train the people on the problem solving skills to be able to understand and execute the process 2. Drive the LMS (Lean Management) culture and develop them to be problem solvers. Provide them the right tools. 3. Ask the right questions! 4. Mentor and follow through daily! 5. The daily mentoring and follow through will develop the mental model we need.... We need to be consistent, persistent and insistent!

In my experience, listen & learn from the senior engineers, they have the hands on experience to specifically narrow the root cause saving time and money

Als ersten Schritt empfehle ich eine klare Definition des Problems. Hierbei ist es wichtig, relevante Informationen und Daten über Symptome, Ursachen, Auswirkungen und Umfang des Problems zu sammeln. Eine genaue Fehlerbeschreibung kann durch Zusammenarbeit mit Instandhaltung, Prozesstechnik und Equipmenttechnik erzielt werden. Durch Verwendung von Fachbegriffen und einer klaren und präzisen Sprache werden Missverständnisse vermieden und die Kommunikation erleichtert.

Correcto, 1er paso siempre es identificar el problema concreto, aunque exista factibilidad o posibilidad que pueda existir otro problema, pero alinearse a uno y trabajar sobre el, y convencerse de el.

Na produção industrial, devemos ter os sentidos bem apurados, pois com eles em dias iremos parcialmente identificar o problema, por exemplo: Aquele barulho bem baixo, aquele travamento, e até mesmo um sinal claro de desgaste, devemos dar toda credibilidade para quem está operando o máquina, ele com toda a experiência pode ajudar muito a manutenção.

In conjunction with this FMEA method is also fruitful to identify the root cause. Other than this, one need to understand the root process and is well versed with the on going situation of the problem. This is so that, any small details would be helping in identify the possible root cause. Once the root cause is identified, one shall compare it with previous or past situations with the similar incident. This is to get any idea of the possible solution which is related to the possible root cause. Fish bone diagram or FMEA would be easier to understand in such situations.

It’s also important to figure out how the causes interact. Some times a problem needs more than one e cause occurring at the same time to happen, others it needs just one or other cause occurring. Based on this analysis, it’s possible to create one or more null hypothesis and test than to confirm what requires action and what can be accepted.

In conjunction with this FMEA method is also fruitful to identify the root cause. Other than this, one need to understand the root process and is well versed with the on going situation of the problem. This is so that, any small details would be helping in identify the possible root cause. Once the root cause is identified, one shall compare it with previous or past situations with the similar incident. This is to get any idea of the possible solution which is related to the possible root cause. Fish bone diagram or FMEA would be easier to understand in such situations.

Being able to replicate a defect or problem is crucial in the problem analysis procedure. Replication helps confirm the existence of the issue. It validates that the problem isn't a one-time occurrence or an anomaly, allowing for a more accurate assessment of the problem's scope and impact. Replicating the problem aids in isolating its root cause. By systematically recreating the steps or conditions that led to the issue, it becomes easier to identify the specific factors contributing to it. Replication also assists in troubleshooting and resolving the problem efficiently. When you can replicate the issue consistently, it becomes easier to test potential solutions and verify their effectiveness

Hilfreich bei der Problemanalyse ist das Ishikawa Diagramm und die Fehlermöglichkeits- und Einflussanalyse. Eine genaue Fehlerbeschreibung in Verbindung mit allen relevanten Daten ermöglicht eine bessere Entscheidungsfindung.

Involving all personnel, from management to operators, when generating solutions to a problem is crucial. Involving all personnel fosters a sense of ownership and buy-in for the solutions proposed. When people feel included in the problem-solving process, they are more likely to actively engage in implementing and supporting the chosen solutions. Including those who will be responsible for implementing the solutions ensures practicality and feasibility. Operators often have firsthand experience with the processes involved, providing invaluable input on what is realistic and achievable and by Involving a diverse group encourages open communication and collaboration. It helps bridge any communication gaps.

Solutions shall be measurable as well as the problem. Crucial question in this step is “which indicators will be affected for the solution proposed?”

Um die beste Entscheidung zur richtigen Lösung des Problems zu treffen, ist es wichtig, dass das gesamte für die Situation relevante Personal mit einbezogen wird. Zeit, Aufwand und die Kosten der verschiedenen Lösungsmöglichkeiten können somit zusammengefasst werden um die Entscheidungsfindung zu erleichtern.

Ter um inter-relacionamento com as áreas envolvidas para gerar soluções é de extrema importância, já que não podemos deixar a fábrica parar

First of all, the solution is based on the principle of having supply to meet certain manufacturing equipment. Because without replacement material there will be no solution independent of the problem to be resolved or the resolution methodology to be used. In other words, before the solution, it must be observed whether there is a replacement supply. Otherwise we will be in a demand cycle with no solution.

Utilize a flowchart-type tree to be able to answer questions prior to testing, after failures or non conformance issues, and after successful testing as well. This helps replicating and validating the problems, as well as setting a baseline for duplicating the process for success.

Se refere a não tomada de decisão por impulso, se faz necessário, reunir uma equipe eficaz e mostrar a real necessidade de troca, reparo ou co.pra, afim de gerar um retorno equiparativo.

Evaluating and selecting solutions is a key process. Having a decision making tool or process and following it to the letter should be one of your basic practices. Test, test, test and then implement!

This step is all about feasibility. If the solution costs more than the problem it doesn’t worth and other solutions need to be analyzed. Sometimes it’s better accept have the problem than waste on “solutions”.

Para chegarmos em uma boa e satisfatória solução deve-se manter um equilíbrio das metas e resultados, devemos também passar tudo para um KPIs de forma simples e fácil de ser interpretado.

Gemba walk would be the best way to improve our process flow and improve our current working practices. One can set a frequency of Gemba walk from once a week to even twice a month, depends on their availability. But things to take note is, any kind of improvement suggestion through the Gemba walk should be thoroughly follow up with reminders.

Never be completely alone in any endeavours. Teams are the best if they function, this way a team can delegate responsibilities and also information. Trust is a must too in teams as you need to be able to let go of some duties to focus on a other matter within the team, taking care that all tasks is delegated to the experts in each field.