Integrating Mistake-Proofing and Problem Solving

Structured Problem-Solving Approach

• Using a structured problem-solving approach like the 8D (or 8-discipline) problem-solving process helps assure mistake-proofing efforts will be successful.
• However, any structured problem-solving approach can be used when mistake-proofing.

Step 1: Use a Team Approach

• Teams need to know their boundaries of freedom or what they are and are not empowered to tackle.
• Boundaries of Freedom are defined by:

• Scope of work.
• Budget.
• Deadline.
• Time constraints.
• Communication methods.

Step 2: Describe the Problem

• Create a clear, complete problem statement.

Step 3: Interim Containment

• Stabilize the current situation. Use a short-term or “band-aid” approach if necessary.

Step 4: Define the Root Causes

• Problem-solving is really about problem-finding or finding the root cause, which is the underlying reason the mistake occurs.
• Techniques to help identify the root cause include:

• The Five-Whys.
• What Is—What Isn’t Analysis.
• Data Collection & Analysis.
• Design of Experiments.

Step 5: Develop (Mistake-Proofing) Solutions

• Brainstorm for solutions.
• Think outside of the box.
• Then, check the potential solution for practicality, feasibility, and cost-effectiveness.

Step 6: Implement the (Mistake-Proofing) Solution

• Use a simple action plan for straightforward solutions.
• Use project management tools for complex action plans.

Step 7: Prevent Recurrence

• Test the solution to make sure the actions worked as expected.
• Assure the solution is robust.

Step 8: Congratulate the Team

• As with any accomplishment, congratulations and recognition are in order.