Effective Problem Solving in Manufacturing: 7-Step Method for Root Cause Elimination
Master systematic problem-solving excellence with our industry-leading methodology training. Develop expertise in root cause analysis, data-driven decision making, and sustainable solution implementation under expert guidance. Transform your approach to complex manufacturing challenges through proven techniques and hands-on application.
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Training Provider Pricing
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What you'll learn
- Use Pareto charts and scatter diagrams to identify and validate root causes
- Define problems as quantifiable gaps and write effective problem statements
- Develop implementation plans with clear milestones and stakeholder buy-in
- Apply Fishbone diagrams and 5 Why technique for comprehensive cause analysis
- Create process flow diagrams and identify critical defect zones accurately
- Generate creative solutions using structured brainstorming and decision matrices
- Establish measurement systems and standardize solutions for sustainability
Why should you attend?
This comprehensive training program equips participants with a systematic approach to identifying, analyzing, and resolving complex problems in electronics manufacturing environments. The methodology emphasizes structured problem-solving techniques that move beyond quick fixes to address root causes effectively. Participants begin by learning to properly define problems as quantifiable gaps rather than symptoms, developing clear problem statements that capture business impact. The course progresses through process mapping techniques, teaching learners to visualize current situations through flowcharts and identify critical defect zones. Data collection methods including tally sheets, run charts, and trend analysis provide the foundation for evidence-based decision making. Advanced analytical tools form the core of the methodology, including Fishbone diagrams for cause brainstorming, the 5 Why technique for deeper investigation, and Pareto charts for prioritizing issues. Participants master root cause identification through scatter diagrams and cross-validation techniques, building compelling problem stories supported by concrete evidence. The solution phase emphasizes creative brainstorming, feasibility analysis, and structured decision-making using scoring matrices. Implementation planning covers action plan development, stakeholder engagement, and resource allocation. The final phases focus on measuring results through Key Performance Indicator comparison, standardizing successful solutions through documentation and visual controls, and establishing sustainable audit systems for continuous improvement.
Course Syllabus
Day 1 - Problem Definition & Analysis
Short Break
15 minsShort Break
15 minsRecap and Q&A
15 minsLunch
1 hourShort Break
15 minsShort Break
15 minsShort Break
15 minsRecap and Q&A
15 minsEnd of Day 1
Day 2 - Solution Implementation & Sustainment
Short Break
15 minsShort Break
15 minsRecap and Q&A
15 minsLunch
1 hourShort Break
15 minsShort Break
15 minsShort Break
15 minsRecap and Q&A
15 minsEnd of Day 2
Ratings and Reviews
Instructor
Sumitha Kannan is a Certified Professional Trainer and Quality Auditor specializing in Strategic Quality Management with a forward-looking focus on Industry 4.0 Quality practices. With over 30 years of experience across Japanese and US-based multinational corporations and Electronic Manufacturing Service (EMS) providers, she brings a wealth of practical expertise in driving quality excellence and organizational transformation. Holding an MSc in Strategic Quality Management from the University of Portsmouth, UK, Sumitha has made significant contributions to the quality management field. Her dissertation on competencies of quality professionals in the Industry 4.0 era was published in the International Journal of Quality and Reliability Management in 2020 and has been cited over 60 times, demonstrating her thought leadership in the evolving quality landscape. She is a Senior Member of the American Society for Quality (ASQ) and holds prestigious certifications including ASQ Certified Manager of Quality/Organizational Excellence (CMQ/OE) and ASQ Certified Quality Auditor (CQA). Additionally, she is a member of the International Professional Managers Association (IPMA), UK. Throughout her distinguished career, Sumitha has successfully implemented transformative quality initiatives that have delivered measurable business impact. Her achievements include establishing Subject Matter Expert (SME) programs to build internal training capabilities, leading inaugural World Quality Month celebrations that fostered cross-functional collaboration and embedded quality ownership across organizations, and achieving dual ISO13485 and ESDS20:20 certifications within a single year. She has also independently managed complex product and technology transfers from the US to Malaysia, earning recognition from major employers including Honeywell. As a trainer, Sumitha has delivered comprehensive programs on critical quality topics including Total Quality Management, World Class Quality Executive, the 7 Basic and 7 New QC Tools, Statistical Process Control (SPC), Failure Mode and Effects Analysis (FMEA), and Supplier Quality Management. Her training philosophy centers on developing skilled, quality-focused, team-spirited workforces equipped with process-driven problem-solving capabilities. She is passionate about breaking down organizational silos and creating awareness among leadership about how quality-focused strategies drive competitive advantage, enhance customer satisfaction and loyalty, and increase revenues. Sumitha offers customized training solutions tailored to specific organizational needs, making her an invaluable partner for businesses seeking to cultivate a culture of quality excellence.
Instructor Reviews
Sumitha possess a deep understanding of QA methodologies, processes, and tools, and her ability to effectively apply this knowledge has been instrumental in improving product quality and ensuring the successful delivery of projects. Sumitha is highly analytical, detail-oriented, and has a keen eye for identifying potential issues and implementing proactive solutions. One of her greatest strengths is her ability to lead, inspire and coach a team.
Sumitha has in depth quality knowledge and crafting quality strategy by cultivating the quality culture and mindset. She initiated the Quality Month within the organization. Her positive attitude created a motivating atmosphere within the team. Work with Sumitha was a true pleasure.
FAQs
Courses you may like
Why should you attend?
This comprehensive training program equips participants with a systematic approach to identifying, analyzing, and resolving complex problems in electronics manufacturing environments. The methodology emphasizes structured problem-solving techniques that move beyond quick fixes to address root causes effectively. Participants begin by learning to properly define problems as quantifiable gaps rather than symptoms, developing clear problem statements that capture business impact. The course progresses through process mapping techniques, teaching learners to visualize current situations through flowcharts and identify critical defect zones. Data collection methods including tally sheets, run charts, and trend analysis provide the foundation for evidence-based decision making. Advanced analytical tools form the core of the methodology, including Fishbone diagrams for cause brainstorming, the 5 Why technique for deeper investigation, and Pareto charts for prioritizing issues. Participants master root cause identification through scatter diagrams and cross-validation techniques, building compelling problem stories supported by concrete evidence. The solution phase emphasizes creative brainstorming, feasibility analysis, and structured decision-making using scoring matrices. Implementation planning covers action plan development, stakeholder engagement, and resource allocation. The final phases focus on measuring results through Key Performance Indicator comparison, standardizing successful solutions through documentation and visual controls, and establishing sustainable audit systems for continuous improvement.
What you'll learn
- Use Pareto charts and scatter diagrams to identify and validate root causes
- Define problems as quantifiable gaps and write effective problem statements
- Develop implementation plans with clear milestones and stakeholder buy-in
- Apply Fishbone diagrams and 5 Why technique for comprehensive cause analysis
- Create process flow diagrams and identify critical defect zones accurately
- Generate creative solutions using structured brainstorming and decision matrices
- Establish measurement systems and standardize solutions for sustainability
Course Syllabus
Day 1 - Problem Definition & Analysis
Short Break
15 minsShort Break
15 minsRecap and Q&A
15 minsLunch
1 hourShort Break
15 minsShort Break
15 minsShort Break
15 minsRecap and Q&A
15 minsEnd of Day 1
Day 2 - Solution Implementation & Sustainment
Short Break
15 minsShort Break
15 minsRecap and Q&A
15 minsLunch
1 hourShort Break
15 minsShort Break
15 minsShort Break
15 minsRecap and Q&A
15 minsEnd of Day 2
Instructor Reviews
Sumitha possess a deep understanding of QA methodologies, processes, and tools, and her ability to effectively apply this knowledge has been instrumental in improving product quality and ensuring the successful delivery of projects. Sumitha is highly analytical, detail-oriented, and has a keen eye for identifying potential issues and implementing proactive solutions. One of her greatest strengths is her ability to lead, inspire and coach a team.
Sumitha has in depth quality knowledge and crafting quality strategy by cultivating the quality culture and mindset. She initiated the Quality Month within the organization. Her positive attitude created a motivating atmosphere within the team. Work with Sumitha was a true pleasure.
Public Pricing
Corporate Pricing
Pax:
Training Provider Pricing
Pax:
Features
Subsidies
Ratings and Reviews
Instructor
Sumitha Kannan is a Certified Professional Trainer and Quality Auditor specializing in Strategic Quality Management with a forward-looking focus on Industry 4.0 Quality practices. With over 30 years of experience across Japanese and US-based multinational corporations and Electronic Manufacturing Service (EMS) providers, she brings a wealth of practical expertise in driving quality excellence and organizational transformation. Holding an MSc in Strategic Quality Management from the University of Portsmouth, UK, Sumitha has made significant contributions to the quality management field. Her dissertation on competencies of quality professionals in the Industry 4.0 era was published in the International Journal of Quality and Reliability Management in 2020 and has been cited over 60 times, demonstrating her thought leadership in the evolving quality landscape. She is a Senior Member of the American Society for Quality (ASQ) and holds prestigious certifications including ASQ Certified Manager of Quality/Organizational Excellence (CMQ/OE) and ASQ Certified Quality Auditor (CQA). Additionally, she is a member of the International Professional Managers Association (IPMA), UK. Throughout her distinguished career, Sumitha has successfully implemented transformative quality initiatives that have delivered measurable business impact. Her achievements include establishing Subject Matter Expert (SME) programs to build internal training capabilities, leading inaugural World Quality Month celebrations that fostered cross-functional collaboration and embedded quality ownership across organizations, and achieving dual ISO13485 and ESDS20:20 certifications within a single year. She has also independently managed complex product and technology transfers from the US to Malaysia, earning recognition from major employers including Honeywell. As a trainer, Sumitha has delivered comprehensive programs on critical quality topics including Total Quality Management, World Class Quality Executive, the 7 Basic and 7 New QC Tools, Statistical Process Control (SPC), Failure Mode and Effects Analysis (FMEA), and Supplier Quality Management. Her training philosophy centers on developing skilled, quality-focused, team-spirited workforces equipped with process-driven problem-solving capabilities. She is passionate about breaking down organizational silos and creating awareness among leadership about how quality-focused strategies drive competitive advantage, enhance customer satisfaction and loyalty, and increase revenues. Sumitha offers customized training solutions tailored to specific organizational needs, making her an invaluable partner for businesses seeking to cultivate a culture of quality excellence.
FAQs
Courses you may like
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