What is Problem solving methodology and how to use it in IATF requirement


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The term A3 used typically problem solving technique which is nothing but provide a structured methodology to solve the any problem and guide to move towards the improvement.

 

The term A3 was originated from Toyota by a lean manufacturing practitioners, basically it helps to diagnoses the situation so that we can focus on your problems and not just on its symptoms.

Let us understand more clear about “what is A3 “and how easily we can make an A3 report.

 

So without wasting any further time let's start our today's article on A3 problem solving methodology.

 

So in this chapter we are going to discuss in brief about


  • What is A3?
  • How it is used as a systematic problem solving tool
  • Origin of A3 methodology
  • History of A3 methodology
  • Why it is A3 why not A4 or A5
  • What is the linkage between A3 and PDCA?
  • Different stages of A3 problem solving technique
  • Format structure and how to do A3 analysis

 

So let’s discuss these all items one by one:

 

What is this A3 report?

This is the first thing which is very important to know that what is A3 before proceeding to next step related to how to fill A3.

A3 is basically a problem solving methodology to solve the any problem and guide to move towards the improvement.

 

The term A3 was originated from Toyota by a lean manufacturing practitioners, basically it helps to diagnoses the situation so that we can focus on your problems and not just on its symptoms.

Let us understand more clear about “what is A3 “and how easily we can make an A3 report.

 

Later on it is followed by all other countries to solve their problems, because it provide easy and straight forward process to resolve the problem and communication of same information to co-workers so that each individual is get aware about issue and the action taken to solve this.

Based on the steps followed to prepare A-3 it can easily linked with PDCA cycle. So A-3 can easily correlate with PDCA cycle that’s why it is named as A-3 not A4, A5, A2 etc.

 

History:

Basically the term A3 is derived from paper size which his used worldwide now a days. A-3 is European paper size which is nearly about the same size as an American 11inch X 17 inch or A B size paper now using an A3 method.

Basically it is a one page improvement project report on A3 by focusing the report length to one page, so that problem solving team will be more concise and considering only useful information in the report  

 

In short A-3 makes report easy to understand and make it relevant to other concerned persons.

 

To understand the relation of A3 problem solving methodology with different phases of PDCA cycle first we have to go through about various stages of A3 problem solving methodology and each step importance.

 

Step -1:

This step involved identification of problem or any issue which we want to resolve. in this step we have to identify how this issue can impact on organization business.in similar manner it need to ensure impact on shop floor with the help of 5W and 1S technique which is basically focus on what, when, where, who, why and how much.

 

Understanding of current situation:

This is the next step of A-3, which help to understand the current situation of the problem under consideration.

This all about for clear understanding of problem addressing by visual etc. That it is important to determine the extent of the problem.

Next step is to develop a goal statement: Goal for any task shall be SMART it means it should be Specific, measurable, achievable, realistic and time bound.

Now next step is conduct root cause analysis and based on identified root cause action to be identified an implementation of action to be ensure do that the problem cannot repeat itself.

 

At the time of action identification of action it ned to ensure that the action are linked with identified root cause and action having a relation with the each cause so that the strong action on each root cause will help to eliminate that particular problem.

 

Now it comes to last step of

 

 last step is to standardize   and improve so during this phase of A3 the team should take actions to standardize the process   changes or improvements the team must update all the standard work work instructions and the   process control plans the management team should also promote continuous improvement of using this   A3 tool within the organization so your goal is to then repeat the implementation plan until your   goal is met now let us map this with PDCA  cycle so these four five phases of initial steps are under plan phase then we have the implementation that is the do phase follow-up and evaluation comes under   check and standardization is the act phase so this is how you map PDCA  with A3 problem solving steps now that we have seen this uh A3 problem solving steps now it's time to look at the   sample A3 format assuming that this is a three layout and here we'll define who is   preparing this report and the date here at the top then we will define the background   as in what is impacting your business right now your customer or your process so you will   define all the detailed background over here and then what is the current situation over there   then what is your goal in the target statement so you will define all your   goals make sure it is the smart code that you are defining here   then you need to do some root cause analysis and you can use the fish bone diagram or the five why technique to come to the root cause then you need to come up with some action or recommendations so   it could have multiple recommendations so keep all your recommendations open at this point of time.


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