Problem Solving Form (DMAIC Lite)
DEFINE
Plant Equipment Date Problem Potential Initiator
Team Members Tracking Number
Describe Problem Start Date:
Completion Date:
What:
When:
Initial Data
Where:
Who:
Problem Statement
MEASURE
In this space insert charts and/or drawings to stratify the problem to the lowest level. Use additional forms if necessary.
ANALYSIS
4-M Analysis [ Brainstorm potential causes of the incident based on data, observation, and experience. ]
huMAN MACHINE
Problem Statement
METHOD MATERIAL
ANALYSIS (Continued)
Why-Why Analysis [ Evaluate "The Critical Few" to identify Root Cause(s). ]
WHY? WHY? WHY? WHY?
f
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ar she
Problem Statement
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POTENTIAL ROOT CAUSES
Rank Potential Root Cause Rank Potential Root Cause
IMPROVE
Countermeasure Ladder
Top Root Cause(s) Countermeasure Level Responsible Target Completion Date Actual Completion Date
CONTROL
CHECK RESULTS REPLICATE AND STANDARDIZE
Countermeasure Time Period Tracked Results Item Required Description Target Date Responsible Completion Date
Std Work/SOP Update Yes No
Educated? Yes No
Update PM? Yes No
Replication Yes No
Yes No
Yes No
Problem Solving Form (DMAIC Lite)
DEFINE
Plant Equipment Date Problem Potential Initiator
Home Car 1/10/2021 Wreck Me
Team Members Tracking Number 1
Describe Problem Flat Tire Start Date: 1/10/2021
Me
Completion Date: 1/10/2021
What: Flat Tire Right front
When: 1/10/2021
Initial Data
Where: Driveway
Who: Me
Problem Statement I got ready to run errands and saw my right front tire was flat
MEASURE
In this space insert charts and/or drawings to stratify the problem to the lowest level. Use additional forms if necessary.
Nails found in this area
ANALYSIS
4-M Analysis [ Brainstorm potential causes of the incident based on data, observation, and experience. ]
huMAN MACHINE
Flat scraper used to pull shingles
New Hires on Job No tools to pick up nails
off - Nails came out at same time
Problem Statement
Flat Right Front Tire
Training procedures non
Rubber Tire Steel Nails
existent
Nails in driveway and yard
METHOD MATERIAL
ANALYSIS (Continued)
Why-Why Analysis [ Evaluate "The Critical Few" to identify Root Cause(s). ]
WHY? WHY? WHY? WHY? WHY?
Contractor did not clean up No Procedures to address
Roofing Nail in Tire Nail in Driveway
nails lost nails
Tire Lost Air No Tools to help find lost
nails
Problem Statement No catch mechanism to catch
wayward nails
Right Front Tire Flat
POTENTIAL ROOT CAUSES
Rank Potential Root Cause Rank Potential Root Cause
1 No procedures to catch lost nails
2 No tools to help find lost nails
3 No catch mechanism to catch wayward nails
IMPROVE
Countermeasure Ladder
Top Root Cause(s) Countermeasure Level Responsible Target Completion Date Actual Completion Date
Develop procedure and educational plan for associates to find
No procedures to catch lost nails 1 Contractor 1/15/2021 1/15/2021
nails
No tools to help find lost nails Purchase and begin using magnet to pick up nails 5 Contractor 1/15/2021 1/15/2021
Design and implement catch mechanism to eliminate nails from
No catch mechanism to catch wayward nails 6 Contractor 1/15/2021 1/15/2021
reaching the ground
CONTROL
CHECK RESULTS REPLICATE AND STANDARDIZE
Countermeasure Time Period Tracked Results Item Required Description Target Date Responsible Completion Date
Std Work/SOP Update Yes No Updated procedures 1/15/2021 Contractor 1/25/2021
Procedure to find nails 3 months No flat tires from customers
Educated? Yes No Educated Team 1/21/2021 Contractor 1/25/2021
No flat tires from customers Update PM? Yes No PM Procedures updated 1/15/2021 Contractor 1/15/2021
Use magnet to pick up nails 3 months
No nails found on driveway Replication Yes No Replicated to crews 1/15/2021 Contractor 1/15/2021
No flat tires from customers Yes No
Catch mechanism 3 months
No nails found on driveway Yes No
