Problem Solving | AllAboutLean.com

Toyota Practical Problem Solving (PPS)—Monitor and Share

Christoph Roser — Tue, 26 Dec 2023 11:00:22 +0000

This post of my series on Practical Problem Solving (PPS) looks at what to do after you have done the “Do” part of PDCA. Yes, that’s right, after implementing the solutions you are not done yet. You need to monitor the outcome to see whether it has actually achieved the target you set much earlier. ... Read more

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Toyota Practical Problem Solving (PPS)—Countermeasures and Implement

Christoph Roser — Tue, 19 Dec 2023 11:00:20 +0000

In this post of my series on the Toyota Practical Problem Solving (PPS), we finally get to the part many were excitedly waiting for—the development of countermeasures and their implementation. Some people like this part of actually doing the improvement (and hence finally the “Do” part of PDCA) so much that they skip the “Plan” ... Read more

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Toyota Practical Problem Solving (PPS)—Targets and Root Causes

Christoph Roser — Tue, 12 Dec 2023 11:00:18 +0000

In the previous posts on this series of the Toyota Practical Problem Solving (PPS) I went into detail on how to understand the problem by clarifying the problem and breaking it down to get the prioritized problem. In this post I will look at target setting and root-cause analysis. Setting the target and doing the ... Read more

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Toyota Practical Problem Solving (PPS)—Clarify

Christoph Roser — Tue, 05 Dec 2023 11:00:14 +0000

In my last post I introduced the Toyota Practical Problem Solving approach (PPS) and gave an overview how it is rooted in PDCA and often used in the form of an A3. Now let’s dig deeper and go into the details of the individual steps. The first is to clarify the problem. The second is ... Read more

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Toyota Practical Problem Solving (PPS)—Introduction

Christoph Roser — Tue, 28 Nov 2023 11:00:14 +0000

Lean is a lot of problem solving. Toyota excels at such problem solving, and they have developed their practical problem solving (PPS) approach. For many it is surprising how much time Toyota spends on defining and understanding the problem, whereas (many in) the rest of the world immediately jump to a (possibly inferior) solution. Let me ... Read more

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Making the Problem go Away Is NOT Improvement

Christoph Roser — Tue, 11 Apr 2023 11:00:34 +0000

Managing problems is an important part of manufacturing because it allows companies to identify and address issues that can impact product quality, production efficiency, and overall profitability. However, it is not to be confused with actual improvement. While taking care of the problem (hopefully) makes the problem go away, actual kaizen requires that the problem ... Read more

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Work Improvement before Equipment Improvement

Christoph Roser — Tue, 05 Oct 2021 11:00:49 +0000

When improving a system, Western engineers love to take the technical approach and to optimize the machines and tools. However, at Toyota this is seen differently. At Toyota, they try to address a problem by first training the people, followed by improving the standards and the layout, before improving the equipment and finally twiddling with ... Read more

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Cardboard Engineering – Alternatives

Christoph Roser — Tue, 27 Aug 2019 11:00:39 +0000

Cardboard Engineering is a quick way to try out different configurations in reality. As the name says, this is done using cardboard. However, there are a few alternatives. Let me show you a portfolio of different ways to make cardboard models with (not only) cardboard, from ultra-cheap to very fancy. Please note that the fancier ... Read more

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