《5_why_lesson_plans》.doc

5-Why Problem-Solving Lesson Plans Terms: 5-Phase Analysis, Problem Reporting and Resolution (PR/R), Global Quality Tracking System (GQTS), 5-Why Analysis, brainstorm, spill, Process Failure Mode and Effect Analysis (PFMEA), Process Control Plan (PCP), Risk Priority Number (RPN), severity, detection, occurrence, Advance Product Quality Planning (APQP) Objective: To use the 5-Why Problem-Solving Process in conjunction with brainstorming to investigate, solve, and report corrective actions in a problem-solving activity. Overview: This module may be used to train individuals in using Step 7 in Section II of the Delphi Automotive 5-Why Problem-Solving Process. It would also be useful as a preliminary activity for APQP document development training (e.g.—PFMEA or PCP) or risk analysis. When using this activity to lead into a PFMEA, PCP, RPN-reduction, or risk-analysis workshop, RPN’s for potential causes may be based on actual customer spills. These should be the first failure modes addressed, as there is real data for how the customer reacted (severity), the frequency of the failure mode (occurrence), and how the failure mode was “missed” (detection). Suggested Materials: overhead projector, flip chart or white board, appropriate markers, individual paper and writing utensil(s), small “prizes” (e.g.—Delphi pens, luggage tags, etc.), two similar but essentially different products manufactured by the same company (e.g.—Coca Cola and Diet Coke, Rugrats macaroni and cheese and plain macaroni and cheese), blank 5-Why Analysis charts (two or three copies for each member of the group), diskettes containing all referenced files and documents (copy for each member of the group), “Information and Product Security” (or similar) videotape, VCR and television, additional video tape if needed, slides from 5-Why Presentation Slides.ppt, all referenced files and documents Referenced Files and Documents: 5-Why Critique Sheet.doc, 5-Why Lesson Plans.doc, 5-Why Analysis Chart