Solve Manufacturing Problems in Only 3 Days!

 

So you’ve seen my video, “How to Solve a Manufacturing Project in 3 Days.” The video dives deep into the Lightning Problem Solving Method. These steps make solving manufacturing problems in under 72 hours more doable and less daunting.

 

But the truth is, there are exceptions to every rule. In my experience, using the Lightning Problem Solving Method you should be able to solve about 90% of projects in only 3 days. In what instances can a manufacturing problem take more than three days to solve?

 

What Might Slow the Process Down?

Situation #1: If you can’t measure a part, or if you have a hard time measuring it.

 

This situation is very common. For example, I once had to measure a curved surface on an assembly line that was going full speed. This one had my head spinning! I would have to measure seven different points on each moving part. To keep up with the assembly line, I needed to create a curved fixture for quick measuring. Fortunately that creation enabled me to measure ten times faster than my normal speed! But needless to say, designing a measuring tool set my timeline back just a bit. If you need to create a special tool or part to solve the problem, expect the project to take more than three days.

 

Situation #2: If you’re having trouble reproducing the event.

 

We talked about the importance of reproducing the event in this video. The part may fail the same way, but you’ll need to confirm that this failure was the same as the field failure.

 

“One time I failed the part, but some wondered if that failure was comparable to the failed parts in the field—I needed to confirm that this failure was the same as the field failure.”

 

In one project, I had to make a special fixture to rotate the part on a lathe to simulate the mechanics of a car. The lathe technician even added a brake to heat the part, simulating an uphill climb with a full load. It was a very involved project, and having the flexible timeline was essential to getting it right. Never sacrifice finding the right root cause just to get the project done faster.

 

Situation #3: If you can’t find contrast.

 

“Maybe they’re all bad and it’s hard to find contrast.”

 

If all the parts are bad, there might not be any good parts to use for comparison. You could even have the opposite problem if bad parts are hard to find. It may be because they have a small failure rate. Or, if parts are taking a long time to fail in the field, your project may stretch longer than three days.

 

If you’re not encountering any of these problems in your manufacturing project, then consider yourself lucky! It means that a Lightning Problem Solving Mastermind should be able to solve your problem in only 3 days! Click here to find out what it takes to become a Mastermind, or check out my video on How to Solve a Manufacturing Project in Only 3 Days.

 

If you need help solving a manufacturing problem lightning fast, get in touch! I offer one-on-one training to improve your problem-solving methods. Check out my other free videos here, and don’t forget to subscribe!