8-Step Scientific Problem Solving and A3 reporting (which is based on the Toyota 8 step methodology) was launched under the tagline “Find a Problem, Fix a Problem, Stop the Problem Coming back”. The goal of the project was to reach a situation where employees were equipped to carry out improvement projects within their areas.
Before the project was launched internally, four employees representing the OpEx, Production, Engineering & Quality Departments were selected to become 8 Step Subject Matter Experts. The team received extensive training from ex-Toyota practitioners, which included applying the methodology to resolve long-standing problems in their own areas. The project then started in a pilot area of the plant with the SME’s delivering one-day training to 10 employees. The next step was to split the group of employees into five smaller teams, with each team tasked with applying the 8-step process to current problems that they had selected and could be completed within 12 weeks. Importantly, on completion of each step, the team had to present their findings and explain their rationale to an 8 Step Review Panel which comprised any two 8 Step SME members. Due to the success of the pilot projects, a roll-out program was developed, which resulted in 100 employees being trained and applying 8-step problem solving annually.
The program proved extremely successful and exceeded expectations to become an excellent conduit for engaging employees at all levels. Front-line employees have embraced the opportunity to participate in problem-solving projects within their areas and their input to root cause analysis, countermeasure development, and implementation is critical.
While 8-step scientific problem solving and A3 reporting has enabled employees at all levels to identify the root cause of problems so that they can be eliminated, reduced, or contained, many other benefits have also accrued:
8-step scientific problem solving and A3 reporting is now very much ingrained in our culture. Each year, over 100 documented problem-solving projects are completed. Customers, suppliers, and other local companies receive training leading to collaborative projects which have strengthened our working relationship. To encourage and promote the use of problem-solving, we have linked it as a personal objective for all team leaders and upwards and included it as part of their annual performance appraisal.
In today's highly competitive environment, implementing a lean culture in your business has never been more important.
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