Frontline Problem-Solving in Manufacturing,
Utilities, Operations and Engineering
Learn how to practically apply structured A4 Thinking to problem-solving
in the manufacturing and industrial environment. Specifically developed for frontline teams.
COURSE OVERVIEW
Frontline problem solvers are taught to apply A4 Problem Solving for the solution of problems encountered in manufacturing, engineering, utilities and operations. The approach is aligned to A3 Thinking as developed and implemented by the pioneers of Lean, Toyota. The A4 approach is however more truncated, making it more suitable for the frontline.
The 6 individual steps in the A4 Problem Solving Process encompass a structured approach to defining, analysing and solving problems that is grounded in lean principles. The course includes exercises and case studies where learners apply the various techniques using examples from the real-world industrial environment.
TARGET AUDIENCE - roles involving hands-on interactions with the process
- Operators
- Artisans
- Laboratory Technicians
- Engineering Technicians
- Store Controllers
- Raw Material Clerks
- Quality Inspectors
- Material Handlers
- Environmental Technicians
LEARNING OUTCOMES
The course is comprised of individual modules that begin with basic concepts and then take participants on a journey through the A4 Problem Solving process.
After completing this module, participants will be able to:
- Explain the linkages and overlaps between manufacturing, utilities, operations, and engineering
- Understand the concepts of “value” and “waste”
- Describe the 8 different types of waste that may be encountered in manufacturing, utilities, operations, and engineering
- Name and describe typical performance areas
- Explain fundamental problem-solving terminology
- Explain how problems are detected
- Explain why the time taken to detect problems is important
- Understand the difference between solving a problem and correcting a problem
- Describe the Plan Do Check Act cycle and how it is applied in practice
- Outline the benefits of problem solving
- Explain who is accountable for problem solving
- Explain when and how to escalate problems that you are unable to solve
- Describe the characteristics of an effective problem-solving team
After completing this module, participants will be able to:
- Explain the need for an overarching problem-solving framework
- Understand the principles behind A4 problem solving
- Describe the key steps in A4 Problem Solving
- Explain how an A4 Problem Solving Record Sheet is used in practice
After completing this module, participants will be able to
- Explain why we need to state the problem and what a problem statement is
- Develop, test, and improve your problem statement using the LOCUS-Q ruleset
- Characterise the problem by assigning it to a Performance Area
- Appreciate the wider role of problem statements in the problem-solving process
After completing this module, participants will be able to:
- Explain the concept of root cause analysis
- Understand the concept of Fundamental Problem Causes
- Explain how to ensure that each possible cause identified is independent of the others
- Use 5-WHY analysis together with fundamental possible causes to identify possible causes and the root cause of a problem
- Explain the concept of “line of sight” when identifying root causes
- Summarise the desirable characteristics of a root cause
- Display a 5-Why in graphical format
After completing this module, participants will be able to:
- Describe, in generic terms, the different types of solutions encountered in the manufacturing, utilities, operations and engineering
- Explain how solutions are developed from root causes
- Explain the importance of risk assessments in solution design and apply simple risk assessment checklists
- Explain how to determine the effort and benefit characteristics of solutions
- Use the Effort-Benefit Chart to choose the most appropriate solution
After completing this module, participants will be able to:
- Explain the different phases of solution implementation
- Describe what is typically involved in implementing different types of solutions
- Understand how to complete the implementation record on an A4 problem solving record sheet
After completing this module, participants will be able to:
- Explain why it is necessary to evaluate the performance of implemented solutions
- Describe the characteristics of an effective solution
- Evaluate an implemented solution
- Decide on how to react if a solution does not solve a problem
- Decide on how to react when a solution is effective
- Explain how organisations learn from each problem-solving event
After completing this module, participants will be able to:
- Describe the purpose of each element of an A4 Problem Solving Record Sheet
- Explain the links between different elements of the A4 record sheet
- Ensure that the individual elements of the A4 Problem Solving Record Sheet are aligned and that the process overall is integrated
COURSE PRICE
Live at an off-site venue with catering
- R7,999 per delegate for groups of 5-15 delegates + costs of facilitator travel – available nationally
Live on customer premises with customer catering
- R6,499 per delegate for groups of 5-15 delegates + costs of facilitators travel – available nationally
Online via Teams or Zoom with live facilitation
- R5,999 per delegate for groups of 5-15 delegates – available globally
COURSE VENUE
The course is offered nationally in South Africa at venues in client cities or on client sites if preferred. Includes a comprehensive, full-colour training manual. Includes refreshments where off-site venues are used.
Facilitator
Craig van Wyk
B.Sc.(Eng), MBA
Duration
1.5 Days
Course Dates
This course is offered
on demand