Search for solutions

1. Search for solutions • Unstructured search • Use group techniques: • Brainstorming • Nominal group technique • Groupware • Videotape analysis • Encourage ideas, discourage criticism • Avoid “groupthink” • Systematic structured search • Structured search using the acronym SEARCH

2. Brainstorming • Leader: State problem clearly • Group: Make suggestions orally • No evaluation at this point • Leader: Reword and write down ideas • Don’t worry about getting every word down • Leader: Encourage participation • Not “everyone gets a turn”, but be sure all have a chance to speak • Group: Evaluate/rank ideas • Use affinity diagrams to group into themes

3. Nominal group technique • Leader: state problem • Individuals: Make suggestions in turn • Be sure all have a chance for input • Leader: display ideas • Group member agrees to wording • Group: vote for best ideas • “Dot” method or ranking • Leader: tally votes • Identify clear winners • Group: discuss top ideas further

4. Groupware • Allows multiple computers to communicate simultaneously. • Permits nominal groups to be at different locations. • Makes information widely available. • May cause information overload.

5. Videotape analysis • Operations are recorded so they can be viewed later • Multiple people can interact during viewing • Operator can explain video to team (autoconfrontation) • Results of meetings may be potential solutions or indications for further analysis

6. Systematic structured search • Identify management’s perception of the problem • Obtain job descriptions, historical data, and management perspective • See for yourself • Walk through and observe • Use a checklist • Obtain information from the operator • Get information from the supervisor • Measure light, noise, dimension, etc.

7. S Simplify operations E Eliminate unnecessary work and material A Alter sequence R Requirements C Combine operations H How often Eliminate unneeded work Eliminate work that is not cost-effective Use the exception principle Use self-service • Quality (capability) costs • Initial vs. continuing costs Structured Search: SEARCH • Provide prepared, written information. • Use jig and fixture designs to simplify machining. • Shift from counting to sampling. • Use forms, email, phone calls. • Generate less waste. • Automate part of a process (e.g. cleaning). • Both general purpose and special purpose materials should be considered. • Specialist job descriptions may be inefficient. • Central departments allow economies of scale. • Advances in communications can be used to centralize. • Supervisors may resist consolidation. • Simplify (or eliminate) other operations • Reduce idle/delay time • Reduce material handling costs • Use economic lot size calculations. • Analyze maintenance, service, and inspection activities. • Use red/yellow/green labels to concentrate resources where needed.