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2017 Problem Solving Panel Discussion
Elena Jacob – Adient U.S. LLC Tony Comella – Supply Chain Services Int’l, LLC
Thomas Lincoln – Cooper Standard Christopher Ottenbreit – NSK Americas
Mark Troup – Volvo Group Trucks Holly Zimmerman – Harley-Davidson Motor Company
Robert Butts – Moderator, Adient U.S. LLC
Background / Purpose
Back ground and Status on AIAG’s CQI-20 / 21 revision project (Effective Problem Solving Practitioner and Leader Guides)
Problem solving panel discussion with industry professionals. Supplier and OEM perspectives/strategies on:
• Systemic problem solving • Culture and personnel • Education and knowledge capture • AIAG survey results • Questions from the audience
Background / Purpose
Agenda Topic Time
Purpose & Background 10 Minutes Moderator Panel Introductions 10 Minutes Problem Solving Panel Panel Discussion / Q & A 30 Minutes Problem Solving Panel 2017 Audience Q & A 40 Minutes Problem Solving Panel Wrap-Up 5 Minutes Moderator & Panel
Background
Results of the 2015 AIAG’s Quality 2020 survey found:
• OEMs and Suppliers rank Problem Solving as the most critical issue impacting Quality today
• 64% of respondents indicated their organizations are, at best, “moderately capable” of effective Problem Solving
“Critical” “Not Very Good at It” “Don’t Know How to Fix It”
November 2015: AIAG launched an Ad Hoc - Problem Solving task force
Background
February 2016: Problem Solving Ad Hoc committee conducted a 2nd survey: - Gather information and texture around problem solving
concerns within the industry - How does one write a Problem Statement on effective
Problem Solving?
Conclusion: Opportunity to improve the existing AIAG Problem Solving Guidelines - adding guidance on items identified as problematic - Leadership / Culture / Roles and Responsibilities
Background / Survey Results
6
Both point to a desire for a rapid answer… but also compromising analysis.
Source: Deloitte AIAG Quality 2020 Study
Reason OEM SUPPLIER
Jumping to the Solution 1 4
Root Cause Analysis Lacking 2 1
Management / Organizational Culture 3 2
Rushed 4 3
Lack Prevention through Lessons Learned 5 5
Not Data-driven 6 7
Not Systemic 7 8
Lack Resources 8 6
Differences emerge when ranking reasons why problem solving is inadequate.
Background / Survey Results
All organizations have a defined problem solving process.
Many organizations do not follow that same process
Background / Survey Results
Customers have an effect on problem
solving effectiveness
Fewer than 50% “Always” consider
systemic root causes
Problem Solving Panel Discussion
Problems take 3 times longer to solve than to prevent
Where should we be focusing our limited resources?
Past Concerns Present Issues Future Planning
Typical Org Majority Some Fewer
World Class Fewer Majority
Time Spent on Issues
A shift from Reactive to Proactive Problem Solving is needed
Problem Solving Panel Discussion
Ad Hoc Committee moved to a Working Group format to Combine, Update, and Revise CQI-20 and CQI-21 New “CQI-xx Guideline” designed to address “real world” feedback from the 2020 and follow up surveys. Result will be one Practitioner Guide: - Leadership and Culture guidance throughout
Problem Solving Panel Discussion
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
From a Supplier perspective, what are you doing in your own organization to improve problem solving capabilities?
Please submit Audience Questions through the provided Question Cards
Problem Solving Panel Discussion
Discipline is key in Problem solving (For example, the ‘D’ in 8-D). As an OEM, what does ‘discipline’ in Problem Solving mean to you?
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
A large number of our survey respondents (~70%) indicate a Customer “affect” on the “effectiveness” of the problem solving process. - What expectations do you have of your suppliers as it relates to problem solving? - What can we, as Customers, do to Help or Hinder the process?
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
We struggle with properly defining the problem…often leading to an incorrect root cause and/or ineffective solution. - Do you have suggestions for better problem statement determination? - How do you know you have the right problem description?
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
If a majority of problems are system oriented, why do you think we focus so much time / energy on specific processes or specific problems than the system itself?
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
How important is learning the specific, systematic, steps for effective problem solving?
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
What do you think of the trend to reduce 8D time to close metrics as required in many Supplier Manuals? Does this, or can this effect problem determination and solution implementation?
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
What suggestions do you have to help drive a consistent Problem Solving culture in a global organization? (Eg: regional differences, cultural norms, time zones, etc).
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
Why is problem solving always Quality’s responsibility? How can we involve other functions to contribute, and support the process?
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
What impact does high turnover and/or a temporary workforce have on a company’s ability to problem solve? How big of a problem do you think this is for industry?
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Attendees Submitted Questions / Discussion
Questions and Comments submitted from 2017 AIAG Quality Summit attendees:
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Wrap-Up
Parting comments from our distinguished panel.
Continued work of the Problem Solving Workgroup needs your help.
Feel free to share additional comments and feedback.
Panel: Elena Jacob Adient U.S. LLC Tony Comella Supply Chain Services Int’l, LLC Thomas Lincoln Cooper Standard Christopher Ottenbreit NSK Americas Mark Troup Volvo Group - Trucks Holly Zimmerman Harley-Davidson Motor Company Moderator: Robert Butts Adient U.S. LLC
Problem Solving Panel Discussion
Thank you for attending our session.