Analysis Toolkit Provides Insight

There are tough, complex and seemingly unyielding problems in every industry. The using various analytic tools, solutions can be found for the most complex problems. Also the analysis will help in unforeseen ways to create a more robust designed product or process in the end.
 
The key to the solution is breaking down what is expected at the most basic and elemental level. First the unwanted symptom must be defined by tangible repeatable measurements to determine the severity and rationalization why action needs to take place.
 
While there are many tools to be used in analysis the following are very powerful:
 

1. Brainstorming
   
2. Process flow diagrams
   
3. Fishbone diagram
   
4. Pareto Charts
   
5. Histographs                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          
   

 
Brainstorming – soliciting ideas for a stated problem for potential causes. (Don’t try to jump straight to solutions, because you may get burned). I think its best to go around the room at least twice before letting it lapse into free form discussion. This way the quiet one in your group may be encourage offering an opinion.
       
         Remember the rules for effective brainstorming.
                 You must limit the scope in stating the problem. Also note for complex problems each part can go thru the brainstorming process the key is breaking it into small pieces.
                The next critical thing is getting input from all effected stakeholders even if the problem does not affect them directly. My feeling is if the problem affects the company’s bottom line everyone is obligated to find a solution.
         (For better efficiency let everyone you invite to the meeting knows the purpose in             advanced and what you expect. Some may submit ideas ahead of time and may be a good jumping off point.)
 
                No critiquing, freewheel and build on other ideas and list them for all to see as you go. Remember to have fun with it, some of the wilder ideas may not be so far out after further review so let it flow.
 
               Try to get at least 20 items or more when the smoke clears. Then you may want to combine some ideas and discuss the merits of others. Keep an open mind as different perspectives may be pointing to the same thing.
 
Remember brainstorming is only a process tool to help you get to a final solution not the only thing to be used.
 
 
Tip if your answers are numerous and address many different issues you may have a poor symptom/problem statement.
 
Fishbone diagram aka Isakawa is a way to graphically illustrate cause and affect relationships in an operation or process. This is a great candidate for brainstorming when a symptom could be generated by causes in several areas. You can also start with the 5 whys once you have your initial list. The following is an example:
 
     Symptom/Problem: Parts being replace at 3 times the expected rate in the field.
 
            In this particular case you may want to get a breakdown of the symptoms causing the replacement. Using the Pareto chart will give you an excellent graphic to investigate what areas to prioritize your focus on resolving.
 
            Using Histogram charts to show when the failures began trending upward and whether this has flatten out or getting worse or better over time. Track your serial numbers/ mfg made date to assess if this was a particular batch (i.e. design change, software iteration, component quality, assembly process, material handling, shipping methods, etc) that had the problem. Also note the geographic location or account type associated with the problem to rule out external environmental factors creating a problem for your system (i.e. temperature, humidity, sun, wind, corrosion, electronic configuration, power fluxing, using product in a stress mode etc.)
 
            Data collection on your devices performance will help you key in on problems before the failure becomes to a critical point. Quality processes put in place at the beginning of a product being develop to its distribution to customers will save your company time, money or business failure.
 
            I’m always interested in various obstacles to projects and if your team needs some help just fill out the contact form and we can discuss your challenges.