Problem-Solving Techniques: in Apparel Factories

Overview

Problem-solving and standardization work hand-in-hand to ensure that benefits attained from Lean transformation projects are sustained through continuous improvement efforts. If a factory doesn’t have standards, however much it problem solves, there will be no continuous improvement and vice-versa.

PDCA (Plan, Do, Check and Act) is a methodology designed to ensure continuous improvement. It is a sequential method of project management that allows for troubleshooting a problem, identifying the root causes, generating and then implementing a solution, and finally standardizing.

Unfortunately, PDCA is not yet a common practice in the apparel industry due to the lack of standards which makes it hard to detect for deviations. PDCA is therefore an important tool for every manager and supervisor providing a scientific approach by breaking down a major problem into smaller jobs which are then methodically dealt with one by one.

This course covers the steps of each phase of PDCA including techniques and formats used in the troubleshooting and solution process. The teaching methodology is set in a simplified yet practical manner to facilitate learning as per the needs of the apparel industry.

Outcomes 

You will be able to:

• Clearly understand the PDCA steps
• Break down major problem into small jobs
• Analyze the key driving forces of a problem
• Distinguish between causes and effects
• Apply catchball game
• Conduct Five Whys and One How
• Root out cause of waste
• Generate ideas and solution to eliminate root cause
• Carry out the steps relevant to Do, Check and Act effectively

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