We had the pleasure of presenting a webinar hosted by Chad Westbrook, a manufacturing engineering manager and AGCO production system manager at AGCO Corporation. AGCO is a full-line manufacturer of agricultural equipment. The company makes everything, including tractors, tillers, sprayers, bailers, and other equipment. Chad joined our own Mark Graban to discuss a different way of thinking about problem-solving. This post is a recap of the presentation - watch the full thing for all the details!

A Structured Approach to Problem-Solving

Presented by Chad Westbrook, AGCO

In this webinar, you'll learn a structured approach to problem-solving using the following tools:

• 5G – A tool used to describe a loss phenomenon
• 5W1H – An approach to the revised phenomenon
• 4M1D – Defining the contributing factors to the revised phenomenon
• 4M1D Confirmation – Validating the contributing factors
• 5 Why’s – Root cause and effective countermeasures
  
  

There are a host of methodologies that businesses use to bring structure to the process of identifying and acting upon opportunities for improvement. You may be familiar with Six Sigma, Kaizen, Lean, Toyota Production System, and others. Although these methodologies differ, the heart of each of them is the continuous improvement model. 

The continuous improvement model reflects the idea that organizations should undertake incremental improvements to services, products, and processes. It is guided by a few core principles:

One thing we hear from leaders who are looking to implement a structured approach to business process improvement is that it is difficult to explain to employees how to spot an opportunity for improvement. There are usually a few straightforward ideas that people point to right away, but once they are taken care of, it can be challenging to spot problems in processes, especially those you engage with every day.

An effective way to overcome this problem is to give employees categories of improvement opportunities to consider. Priming the pump with some examples and providing some questions to ask is an excellent way to get people thinking creatively. Of course, every business is different, and all of these examples might not apply to you, but here are 30 ideas that might spark a few of your own.

I often find myself falling into the common trap of believing that if something is worthwhile, it is necessarily difficult. I think we all expect that valuable things are hard. The truth is, however, that sometimes the most effective and impactful things we can do are really quite simple.

When it comes to continuous quality improvement, this is absolutely the case.

Here are 9 examples of quality improvement tools, techniques, and technology that are uncomplicated yet extremely valuable.

Manufacturing organizations dedicated to continuous improvement look for opportunities to eliminate waste at every juncture. They may spend most of their time looking at core activities like production efficiency because improvements to essential processes result in significant gains.

However, there are many activities on the margins that can also be a significant source of waste. Improvements to these tasks might not yield monumental results, but the good news is they can be improved with just a little bit of attention and effort.

Is it possible that you might have opportunities for improvements hiding in plain sight? Here are a few places to look.

If you think trying to predict anything that will happen in 2021 is insane after what’s happened this year, you have a point. But by applying the lessons learned from 2020 and some strong trends that make sense in this new normal, we think we have a reasonably good idea about what to expect concerning continuous improvement next year.

Here are our predictions. We’ll check back in a year to see how close we came.

One of the most important responsibilities of managers in manufacturing environments is to contain costs. The most obvious cost to eliminate is the cost of low quality. Defective products and lost labor hours add no value to the customer and represent a significant strain on the organization.

To eliminate the waste of low quality, a strategic approach to improvement is essential. Here are six steps that support quality improvement in a meaningful, sustainable way.

We all identify goals to improve ourselves in some way. Whether our goal is to eat better, exercise more, spend more time with our family, or increase our productivity, we all have something we're striving for. Although in too many instances, we lose sight of our goals and fall back to old behaviors and the same results.

Continuous improvement is no different. So many organizations set out on a journey of continuous improvement with gusto and quickly lose momentum, causing their initiative to struggle. How do you prevent your organization from slipping back into bad habits? A sustaining culture of continuous improvement is supported by strategic goal setting.

The principles of Lean and continuous improvement methodologies originated from manufacturing, but there’s no doubt that they have been applied to other industries quite successfully, such as nuclear energy. The nuclear industry believes that there is no defect or opportunity that is too small to go after, and there’s always room for improvement. This important principle is a cornerstone belief of what many refer to as a High-Reliability Organization or HRO. 

When people think of structured continuous improvement methodologies like Lean and Six Sigma, they usually associate it with manufacturing. However, these days, financial services firms, under immense pressure to reduce operational costs and improve efficiencies and effectiveness, are embracing formal continuous improvement programs. Many of the most popular methodologies can easily be tailored to the needs of financial services firms. They can also take advantage of the technology leveraged in other sectors to support improvement.