7-Step Problem Solving

How do you cope with problems? Do you have a systematic, agile, and effective way to solve them? This time I want to share a 7-step problem-solving methodology introduced initially by the Automotive Industry Action Group (AIAG). A few companies that I know have adopted 7-step problem solving as a proven method for their production.

The detailed step-by-step process is as follows:

• Step 1: This step aims to identify the problem and then assess its impact on end-users (e.g., product buyers, product users). Sometimes, there may not be a problem. For instance, an experiment with an engineering work or negative testing took place.
• Step 2: Once it’s identified as a problem, we find possible causes that create the problem. Possible causes could be anything relevant with likelihood, relying on experience and expertise. We then narrow down possible causes to 2–3 potential causes.
• Step 3: This step aims to contain the impact on end-users and get back in service. To this end, it requires a short-term solution that patches the potential causes.
• Step 4: An assignable cause is selected with the highest probability among the potential causes. This step works jointly with Step 5.
• Step 5: This step devises a robust solution by running several rounds back and forth from Step 4.
• Step 6: The outcome of the step is to put the solution in place and validate it thoroughly.
• Step 7: We keep watching, making the solution permanent.

Problems in a system appear as one of six failure modes: no function, partial function, over process, intermittent function, degraded function, and unintended function. A failure mode has one or more assignable causes. Each assignable cause is measurable and controllable. Assignable causes ultimately lead to the systemic root cause that is most likely either the relevant process did not exist, it was not adequate, or it didn’t take place.

As seen in Figure 1, problems flow out from the verification and validation step. They are quickly under control. On the other hand, issues reported by end-users are time-critical, requiring a step-3 solution to be put in place immediately. In both cases, 7-step problem solving plays a crucial role in problem resolution.

Figure 1. System development workflow and issue flow

In conclusion, 7-step problem-solving intertwining with a development cycle helps achieve agile productivity.

Reference: aiag.org