1. 6 Step Problem Solving Process1 2 3 4 5 6
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6 Step Problem Solving Process

2. 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
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6 Step Problem Solving Process

3. 6 Step Problem Solving Process
11/20/2014
6 Step Problem Solving Process

4. 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?
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6 Step Problem Solving Process

5. 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?
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6 Step Problem Solving Process

6. 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
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6 Step Problem Solving Process

7. 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
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6 Step Problem Solving Process

8. 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”
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6 Step Problem Solving Process

9. 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?
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6 Step Problem Solving Process

10. 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?
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6 Step Problem Solving Process

11. 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?
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6 Step Problem Solving Process

12. 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?”
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6 Step Problem Solving Process

13. 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
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6 Step Problem Solving Process

14. Problem Tracking Spreadsheet
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6 Step Problem Solving Process

15. P14453 – Journal Bearing Test Rig
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6 Step Problem Solving Process

16. 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)
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6 Step Problem Solving Process

17. 6 Step Problem Solving Process
Back-up
11/20/2014
6 Step Problem Solving Process