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The following process for problem solving is much as is taught during most TPM sessions, however after implementing the
process during an actual problem solving exercise relating to block quality we have added a few changes to enhance the
process. Although not significant, hopefully they will allow the process to be applied with a certain degree of ease.
If data in the form of charts/graphs has been generated such as minor stoppage data, pareto, performance etc then it is
necessary to carry out data stratification so as to identify the area/equipment to focus the problems solving technique. To
help understand the process of data stratification, the following example will help explain the process:
DATA STRATIFICATION TECHNIQUE
The chart shown represents the % of breakdowns recorded from roadside assistance groups in the UK. In data
stratification, it is necessary to determine what influences the worst bar from the chart. Therefore what are the breakdowns
associated with the AA. (Stratify the data from the first chart) The next chart indicates the types of breakdowns associated
with the AA. From the chart it can be seen that Elec. Fault are the largest cause.
50
45
40
35
30
25
20
15
10
5
0
60
% B reakdowns
50
40
30
20
10
AA
RAC
G/F lag
Others
0
Elec.
Mech.
Accident
Others
Next we stratify this data (Elec.) to determine what are the causes of all electrical faults/breakdowns. From the chart it is
clear to see that the main influence for elec. faults is that due to battery faults. To determine the route cause of battery
faults, it is necessary to again stratify the data as shown. After stratifying the data for a fourth time we see that the majority
of breakdowns experienced by the AA are attributed to alternator problems
80
60
70
50
60
40
50
30
40
30
20
20
10
10
0
0
Battery
Fuel Sys
Immobil
Others
Alter
Earth
Charge
Others
From the data stratification, it has been possible from the example shown to identify the root cause of the main breakdown
causes. The following process can be used to identify a problem were no charted data has been collected, and to explore
further (in this case) what causes alternator faults.
WHEN
WHERE
WHO
WHICH
HOW
3.
4.
5.
Does one shift encounter the problem, but the other shifts
dont
Using the 5W & 1H questioning technique above, it is possible to develop a problem statement which will lead to a
better understanding of the problem and hence a solution.
Once a problem statement has been developed it is necessary to determine the potential causes of the problem.
To aid this process, write the problem statement on a flip chart then undertake to carry out a brainstorming exercise
and hence produce a list of possible causes.
BRAINSTORMING
RULES FOR BRAINSTORMING
Go for Quantity
Freewheel
Full Participation
No Criticism
No Evaluation until the end
Record Everything
Cross Fertilise
6.
Once a list of possible causes has been produced, it is necessary to cluster them into one of four main categories as
described under the Fishbone Diagram or 4M Chart as shown, where the major cause can be Manpower, Machines,
Methods,
Materials.
MAJOR
MAJOR
CAUSE
CAUSE
MINOR
CAUSE
EFFECT
PROBLEM
MINOR
CAUSE
MINOR
CAUSE
MAJOR
CAUSE
7.
8.
With each major cause identified, now as a group determine what factors influence the major causes.
Using the Fishbone or 4M Chart as above, progress to transfer all the data onto it, with the problem statement in the
box at the mouth of the diagram.
9. At this stage, it would be necessary to evaluate all the causes so as to determine which are directly influencing the
problem statement. However, it is at this stage that we wish to introduce the FOG Factor
10. The FOG Factor is a method used to identify data and its influence on the problem statement, were FOG stands for:
F = FACTS
O = OPINIONS
G = GUESSES
11. Once the FOG Factor has been applied, it is necessary to address all those causes identified as having significant
impact on the problems statement and therefore need to be analysed using 5Why Analysis.
12. 5Why analysis involves taking the causes and asking why five times so as to get to the root cause of the problem. To
help record the information, use the sheets provided.
13. Once the root cause for all the causes have been determined from 5Why Analysis, they are then transferred to a
recording sheet which indicates the action, person responsible and when action to be completed.
14. Applying this process will ensure that every success is achieved in resolving the problem identified.
1ST WHY
2ND WHY
3RD WHY
4TH WHY
5TH WHY
ALL OUTCOMES IN THE 5TH WHY ARE RECORDED ON THE ACTION RECORD SHEET.
BY WHO
DATE