Tag: Improving OEE

How to Solve Problems with Idea Maps

FreeMind 0.9.0 RC4 - Mind Map with User Icons
Image via Wikipedia

Problem solving is a problem in itself for many companies and at times can be one of the most daunting tasks to undertake during the course of an otherwise regular work day.

For some, problems seldom occur while for others this may, unfortunately, be a daily activity.  Since problem solving is not usually part of the typical daily agenda of “routine” activities, our ability to find the time and solve them efficiently and effectively is compromised.

For many, just finding time seems to be one of the greatest challenges and perhaps a problem to be solved in itself.  Sweeping problems under the rug may be efficient but it is certainly not effective.  (So … broom is not the solution we’re proposing).

Using IDEA Mapping Techniques can help you solve problems effectively and efficiently.  IDEA Maps, Process Maps, and Mind Maps are variations on a theme.  We may use the terms interchangeably in the discussion that follows.

Background:

While there are several different approaches and “forms” that can be used to manage the overall problem solving process, the two most critical steps that will determine the effectiveness of the solution are:

  1. Define a Clear and Concise Problem Description / Statement
  2. Determine the Root Cause(s) of the problem defined by the Problem Statement.

While the first step seems relatively simple, the second step requires a little more effort.  There are at least two (2) root causes for most problems that stem from two simple questions:

  • Why Made?
  • Why Shipped?

These questions imply that defective product was made for a reason (process) and it was shipped to the customer undetected (system).  In other words, the customer is not protected from receipt of defective product.

The root cause analysis process forms the basis for all subsequent problem solving activities, including verification, interim and long term corrective actions.  A lot of time can be wasted simply because the real root causes were never identified.

Problem Solving Tools for Root Cause Analysis:

Many different tools can be deployed during the Root Cause Analysis process including Ishikawa Diagrams (Fishbone Diagrams), 5 Why (discussed in a previous post), Fault Tree Analysis, Q&A (Question Board), and Brain Storming to name just a few.

Mind Mapping or Process Mapping is a technique that provides an unconstrained approach to the thinking process for multiple input and contribution streams.  Maps can also be used to identify interactions or relationships to other elements.

Mind Mapping (Process Mapping)

The center of the map contains the problem statement.  We then surround the problem statement with potential inputs or contributors to the problem.  These statements in turn become the “center” of additional levels of inputs and contributors.  In some respects, the process map can be very similar to a Bloom Diagram and certainly supports the logic found with fishbone diagrams.

The   The draw back to “Mapping” is that most are usually developed on Whiteboards and not easily or readily translated into a software solution.

Software Solutions and Templates

While there are many spreadsheet based solutions, few provide an effective interface to support the use of mapping techniques.  Even most fishbone diagrams developed in Excel are quirky and awkward at best.

While we typically do not endorse specific software solutions, however, FREEMIND is one software that we consider to be among the best of available solutions and can be downloaded free of charge.  The download and installation process only requires a few minutes.

The developers of FREEMIND provide a clean, intuitive solution for creating and maintaining process or mind maps.  While other commercial packages are available, FreeMind is more than capable of handling most problem solving challenges and quite simply is time and money well saved.

The FreeMind homepage provides a better description of the software and it’s capabilities than we could provide here.  Our goal was to introduce “Mapping” as an effective and efficient tool that can be used in the problem solving process.

After spending some time with the software, you will quickly discover that there are many other opportunities where this software can serve you.  We have a mind map that we use to manage weekly and daily reports, another for key metrics, and yet another for our business structure.  The ability to use hyperlinks makes it an easy process to access external reports and resources .

The FreeMind main page provides an excellent overview and provides examples of their software in action.  This is definitely worth looking into and may just save some time for real problem solving.

We are presently using FreeMind version 0.9.0 RC 6.

Home: http://freemind.sourceforge.net/

Copyright 2000-2009 Joerg Mueller, Daniel Polansky, Christian Foltin, Dimitry Polivaev, and others.

Click here to see a sample process map to achieve delivery of 100% on time – in full:  Mapping with FreeMind.  We have also uploaded two documents (one of the original map and a word document showing a pictorial of the mind maps we created) into our Free Downloads box.  See the ORANGE box on the sidebar to get your copy.

If you have a copy of FreeMind, simply change the extension on our Delivery file from “.txt” to “.mm”  Of course, don’t type the quotes.  This is just a sample for example purposes only.  Feel free to edit or modify these files  in any manner you choose.

If you would like to learn more about IDEA Mapping we would encourage you to also read Idea Mapping – How to Access Your Hidden Brain Power, Learn Faster, Remember More, and Achieve Success in Business by author Jamie Nast (twitter:  @JamieNast) or you can visit the website at:  http://www.ideamappingsuccess.com/.

Click here to review or purchase your copy of Idea Mapping: How to Access Your Hidden Brain Power, Learn Faster, Remember More, and Achieve Success in Business

Until Next Time – STAY lean!

IDEA Mapping, Published by John Wiley & Sons, Inc, Hoboken, New Jersey, Published simultaneously in Canada (ISBN-13:  978-0-471-78862-1, ISBN-10:  0-471-78862-7), 268 pages.  The book includes a companion CD-ROM featuring a 21 day trial for Mindjet MindManager 6.
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Cost Weighted OEE and other free OEE Spreadsheet Templates

OEE Spreadsheet Templates – One Click Closer:

As the days of summer are upon us, we thought it would be good idea to make it easier for you to access our free downloads so you can spend more time doing the things you want to do.  We have updated our site and we are pleased to offer you four ways to download our OEE spreadsheet templates:

  1. We added a new page titled “Downloads
  2. We also added a new Link List to the sidebar titled “Download Files”
  3. We made the FREE DOWNLOADS orange Box file a little larger and easier to read.
  4. We will include direct access links in the content of our posts.

Your OEE templates are literally a click away – saving you time and effort.

Cost Weighted OEE – Advanced OEE Template

We have received numerous requests for our “Cost Weighted OEE” template.  Many people are starting to realize that the OEE factors for availability, performance, and quality are not directly correlated.  Of course, we have also discussed our concerns in this regard on several occasions and will state again that OEE is not a stand alone metric.  As a vantage point metric, it can provide a valuable perspective on operations in real time, however, it is only one part of the overall equation.

Rex Gallaher wrote an excellent article titled “OEE Oxymoron; Are all factors truly equal?” that was published by ReliablePlant.com on February 18, 2009.  This article also conveys the premise that the OEE factors are not equal.  Understanding the financial impact of each of the OEE factors will assure that efforts and energy are focused on activities that will provide the greatest return on investment for your company.

To celebrate our site updates, we thought we would give you at least one more reason to see how our download venues work.  A copy of the Cost Weighted OEE Template is now available through all three of our download venues or you can Click HERE to get immediate access to the file.

For a detailed discussion of OEE and how it can (and should not) be used to identify opportunities to eliminate waste and reduce costs, click on one of the links below:

  1. OEE and Cost Control – Published in December, 2008
  2. 6 Things OEE is NOT! – Published in April, 2009
  3. Make or Break with OEE – Published in May, 2009

In light of the current economy, many companies have been forced to look inward to find “new” money.  OEE is one of the few lean metrics available that can help your organization to focus on the greatest opportunities with measurable returns.  We trust the templates and spreadsheet solutions that we offer here will help you in your quest.

For more information, click on the Categories section of the sidebar to search for other articles on our Blog that may be of interest to you.  They can provide significant insight into the many aspects of operations and OEE and may serve as part of your ongoing training efforts.

We appreciate your feedback.  Please feel free to leave a comment or send an e-mail with your suggestions for a future topic, comments, questions, or concerns to leanexecution@gmail.com or versalytics@gmail.com

Until next time – STAY lean!