6 Step Problem Solving Process 1 2 3 4 5 6 11/20/2014 6 Step Problem Solving Process

Why Use a Problem Solving Process? Upfront thought & planning of what is “the problem” helps prevent misdirected decisions & actions which May not solve the problem May delay project completion May result in a bad grade for MSD students (worse in industry) The PSP works well with Teams since all members get involved Can be used anytime the “desired state” is not realized The PSP should be used on the most serious problems since rigor is involved Helps in solving technical or non-technical problems 11/20/2014 6 Step Problem Solving Process

6 Step Problem Solving Process 11/20/2014 6 Step Problem Solving Process

Identifying & Selecting Problem PSP Step 1 The Team develops a statement of the problem Problem statement is clearly understood by all Team members - very important! The Team may also develop a statement of the “desired state” to be achieved by solving the problem This step involves exploring, clarifying, describing & developing an understanding of the problem Tools commonly used are Brainstorming -- Weighted Voting Brain Writing -- Interviewing Surveying -- List Reduction Others? 11/20/2014 6 Step Problem Solving Process

Analyzing the Problem PSP Step 2 The Team needs to specify & collect the data necessary to analyze the problem The Team identifies the key causes This step involves assembling & evaluating the information, gathering the facts & diagramming data Tools commonly used are Histograms -- Pareto Analysis -- Check Sheets -- Process Flow Diagrams -- Cause & Effect Diagrams (a.k.a. Fishbone Diagrams) -- Others? 11/20/2014 6 Step Problem Solving Process

Example – “Car won’t start” We get into our car, put the keys into the ignition, turn the key, and the car won’t start Everyone in the car agrees the problem is that the “car won’t start” – PSP Step 1 The “Car Team” brainstormed what could cause the car not to start Dead battery -- Broken starter -- Loose terminal Starter cable off -- Broken ignition switch -- Bad starter Bad alternator -- Loose alternator belt -- others? From the above, a “check sheet” was formed and the Car Team checked out all of the above & it was a found to be a “loose alternator belt” – PSP Step 2 11/20/2014 6 Step Problem Solving Process

Are we ready to go to PSP Step 3? Are we done asking “why”? Is the loose alternator belt the “root cause”? “Why” is the alternator belt loose? List some reasons “why” the alternator belt could be loose. Loose nut on alternator pivot arm Belt stretched in length Tension idler out of adjustment Others? Confirmed that the nut on “the pivot arm was loose?” Are we now ready to go to PSP Step 3? Most likely yes and on to PSP Step 3 11/20/2014 6 Step Problem Solving Process

Generating Potential Solutions PSP Step 3 Team produces as many ideas to solve the cause of the problem - wild ideas are welcome This step involves non-evaluative thinking Building on Others Ideas -- Elaborating Creative Thinking -- “off the wall” ideas Tools commonly used are Brainstorming -- Brain Writing Benchmarking -- Brainstorming Interviewing -- others? Brainstorming…”in case we forget” 11/20/2014 6 Step Problem Solving Process

Generating Potential Solutions PSP Step 3 The Team decided to use “brainstorming” to generate a list of possible problem solutions Do’s and Don’ts of “brainstorming” No evaluation of ideas during the brainstorming session “off the wall” ideas are valuable and encouraged Build on others ideas to create new ideas Quantity 1st and Quality later List of “brainstormed” solutions Add a lock washer under nut -- Put Elmer’s glue on thread Use a “keeper” nut -- Tension belt & weld pivot arm Others? 11/20/2014 6 Step Problem Solving Process

Selecting & Planning Solution PSP Step 4 Team objectively decides on & plans optimum solution Tools commonly used to decide on the solution List Reduction -- Weighted Voting Criteria Weighting Form -- Balance Sheet Cost/benefit Analysis -- Paired Comparison ***Pugh Concept Selection*** Tools commonly used to plan the solution Gantt Chart -- PERT Chart Flowchart -- others? 11/20/2014 6 Step Problem Solving Process

Implementing the Solution PSP Step 5 Team to implement the selected solution in PSP Step 4 Team to monitor the solution according to the plan in PSP Step 4 Tools commonly used to implement the solution Action Item list -- Data Collection Progress Reports -- Progress Against Gantt Others? 11/20/2014 6 Step Problem Solving Process

Evaluating the Solution PSP Step 6 The Team learns how effective its solution solved the problem The Team reports on what has been accomplished & asking such questions as “will the problem stay solved?” “does the implemented solution cause other problems?” 11/20/2014 6 Step Problem Solving Process

Problem Tracking Methods There are several methods which could be used to track problem resolution using PSP Problem Tracking spreadsheet (especially if you are tracking multiple problems) presented at weekly meetings Action Item spreadsheet with a PSP column for Step Number Line item on a Gantt Chart with 6 mileposts Other methods agreed upon with the Team and the Guide 11/20/2014 6 Step Problem Solving Process

Problem Tracking Spreadsheet 11/20/2014 6 Step Problem Solving Process

P14453 – Journal Bearing Test Rig 11/20/2014 6 Step Problem Solving Process

6 Step PSP = Senior Design Problem Solving Process Senior Design 1) Identifying & Selecting Problem - PSP Step 1 2) Analyzing the Problem - PSP Step 2 3) Generating Potential Solutions - PSP Step 3 4) Selecting & Planning Solution - PSP Step 4 5) Implementing the Solution - PSP Step 5 6) Evaluating the Solution - PSP Step 6 1) Understanding Customer Needs (MSD 1) 2) Developing Specifications (MSD 1) 3) Brainstorming Solutions to meet Customer Needs (MSD 1) 4) Pugh Concept Selection & SDR/SSDR/DDR (MSD 1 & 2) 5) Ordering/Building Systems, Parts & Components (MSD 2) 6) Testing/Reporting on Selected Concept (MSD 2) 11/20/2014 6 Step Problem Solving Process

6 Step Problem Solving Process Back-up 11/20/2014 6 Step Problem Solving Process