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The A3 Workbook ─ Unlock Your Problem-Solving Mind
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Encouraging efficiency, clarity, and disciplined thinking, A3 Problem Solving identifies a problem, describes the objective, and summarizes fact finding and action steps, all on a single A3-sized piece of paper. This approach provides all employees at all levels with a method to quickly identify a problem, analyze it to root cause, select appropriate countermeasures, and communicate necessary actions to decision makers.
The A3 Workbook: Unlock Your Problem-Solving Mind is designed to teach A3 Problem Solving to workers at every level of an organization. Uniquely qualified to author this workbook, Daniel Matthews is an expert trainer with 30 years of training experience including Lean implementation and Training within Industry (TWI). Fourteen of those years he spent with the Toyota Company, which created and made use of the A3 as a core component of continuous quality improvement.
This workbook provides a practical tool for solving specific problems or for making a specific proposal, while also encouraging the development of a corporate culture that empowers all employees to support continuous improvement. The workbook follows the progression of a basic A3 Problem Solving format, offering instructions every step of the way. To reinforce learning, it includes —
Case studies that readers can use to complete A3s
Tips on how to improve the readability of A3s
Examples of Problem Solving A3s, and a Proposal A3
Exercises to reinforce what’s learned
Worksheet templates that can be reproduced for future problem solving
An effective problem-solving process is a critical part of implementing efficient business practices and a problem-solving culture is a fundamental component of empowering employees to support business improvements. Both of these components, taken together, can help any organization make continuous improvements on the long journey to creating a more productive and profitable business.
The A3 Workbook: Unlock Your Problem-Solving Mind is designed to teach A3 Problem Solving to workers at every level of an organization. Uniquely qualified to author this workbook, Daniel Matthews is an expert trainer with 30 years of training experience including Lean implementation and Training within Industry (TWI). Fourteen of those years he spent with the Toyota Company, which created and made use of the A3 as a core component of continuous quality improvement.
This workbook provides a practical tool for solving specific problems or for making a specific proposal, while also encouraging the development of a corporate culture that empowers all employees to support continuous improvement. The workbook follows the progression of a basic A3 Problem Solving format, offering instructions every step of the way. To reinforce learning, it includes —
Case studies that readers can use to complete A3s
Tips on how to improve the readability of A3s
Examples of Problem Solving A3s, and a Proposal A3
Exercises to reinforce what’s learned
Worksheet templates that can be reproduced for future problem solving
An effective problem-solving process is a critical part of implementing efficient business practices and a problem-solving culture is a fundamental component of empowering employees to support business improvements. Both of these components, taken together, can help any organization make continuous improvements on the long journey to creating a more productive and profitable business.
目次
IntroductionThe Origin of A3A3 FormatsFolding the A3How A3 Fits into Your Organization
OverviewA3 Problem-Solving OverviewA3 and the PDCA CycleDefinition of a ProblemTypes of ProblemsHow Problems Come to Us
Problem SituationIntroductionBackgroundStandard Production Standards Exercise Office Standards ExerciseCurrent Situation ExampleDiscrepancy Example Production Problem Statement Exercise Office Problem Statement ExerciseExtent Tank Weld Scenario ExampleRationale Example
TargetThe Difference between Targets and GoalsStructure of an Effective Target Example Target Statement Exercise
ThemeGeneral Theme CategoriesCreating the Theme Theme Statement Exercise
Loud-&-Clear SpeakerPractice Case StudyCause Analysis5-WhyCause Analysis Process Example ExampleDetermining Root CauseTherefore Test Production 5-Why Exercise Office 5-Why Exercise
CountermeasuresSelecting the "Right" CountermeasuresBrainstorming CountermeasuresNarrow Countermeasure ListEvaluate Remaining Countermeasures Effectiveness Feasibility ImpactSelecting Countermeasure(s) ExampleImplementationThe 3-Cs for SuccessCreate the Plan List Required Steps Example Sequence Required StepsCommunicate the PlanCarry out the Plan Assessment Assignment AccountabilityFollow-upEvaluating the ResultHow to CheckWhen to CheckRecommended Actions
Putting It All TogetherDave’s Fabrication Case Study: Part ADave’s Fabrication Case Study: Part BDave’s Fabrication Case Study: Part CDave’s Fabrication Case Study: Part DDave’s Fabrication Case Study: Part EImprove Your A3’s EffectivenessSequencing the Flow of an A3Common A3 Visuals Basic Equations Line Graphs Data Tables Pareto Charts Example Pie Charts Pictograms Sketches and DrawingsVisuals Practice Line Graph Exercise Data Table Exercise Pareto Chart Exercise Pie Chart Exercise Pictogram ExerciseTitan Case Part A: A3 with Visuals PracticeTitan Case Part B: A3 with Visuals PracticeAppendices:Production Standards Exercise AnswersOffice Standards Exercise AnswersProduction Problem Statement Exercise AnswersOffice Problem Statement Exercise AnswersTarget Statement Exercise AnswersTheme Statement Exercise AnswersLoud-&-Clear AnswerProduction 5-Why Exercise AnswersOffice 5-Why Exercise AnswersLine Graph Exercise AnswerData Table Exercise AnswerPareto Chart Exercise AnswerPie Chart Exercise AnswerPictogram Exercise AnswerDave’s Fabrication Blank A3Dave’s Fabrication A3 AnswerTitan Blank A3Titan A3 Answer5S Problem Report A3Food Service Proposal A3Maintenance Training Proposal A3Blank Problem-Solving A3 Format
OverviewA3 Problem-Solving OverviewA3 and the PDCA CycleDefinition of a ProblemTypes of ProblemsHow Problems Come to Us
Problem SituationIntroductionBackgroundStandard Production Standards Exercise Office Standards ExerciseCurrent Situation ExampleDiscrepancy Example Production Problem Statement Exercise Office Problem Statement ExerciseExtent Tank Weld Scenario ExampleRationale Example
TargetThe Difference between Targets and GoalsStructure of an Effective Target Example Target Statement Exercise
ThemeGeneral Theme CategoriesCreating the Theme Theme Statement Exercise
Loud-&-Clear SpeakerPractice Case StudyCause Analysis5-WhyCause Analysis Process Example ExampleDetermining Root CauseTherefore Test Production 5-Why Exercise Office 5-Why Exercise
CountermeasuresSelecting the "Right" CountermeasuresBrainstorming CountermeasuresNarrow Countermeasure ListEvaluate Remaining Countermeasures Effectiveness Feasibility ImpactSelecting Countermeasure(s) ExampleImplementationThe 3-Cs for SuccessCreate the Plan List Required Steps Example Sequence Required StepsCommunicate the PlanCarry out the Plan Assessment Assignment AccountabilityFollow-upEvaluating the ResultHow to CheckWhen to CheckRecommended Actions
Putting It All TogetherDave’s Fabrication Case Study: Part ADave’s Fabrication Case Study: Part BDave’s Fabrication Case Study: Part CDave’s Fabrication Case Study: Part DDave’s Fabrication Case Study: Part EImprove Your A3’s EffectivenessSequencing the Flow of an A3Common A3 Visuals Basic Equations Line Graphs Data Tables Pareto Charts Example Pie Charts Pictograms Sketches and DrawingsVisuals Practice Line Graph Exercise Data Table Exercise Pareto Chart Exercise Pie Chart Exercise Pictogram ExerciseTitan Case Part A: A3 with Visuals PracticeTitan Case Part B: A3 with Visuals PracticeAppendices:Production Standards Exercise AnswersOffice Standards Exercise AnswersProduction Problem Statement Exercise AnswersOffice Problem Statement Exercise AnswersTarget Statement Exercise AnswersTheme Statement Exercise AnswersLoud-&-Clear AnswerProduction 5-Why Exercise AnswersOffice 5-Why Exercise AnswersLine Graph Exercise AnswerData Table Exercise AnswerPareto Chart Exercise AnswerPie Chart Exercise AnswerPictogram Exercise AnswerDave’s Fabrication Blank A3Dave’s Fabrication A3 AnswerTitan Blank A3Titan A3 Answer5S Problem Report A3Food Service Proposal A3Maintenance Training Proposal A3Blank Problem-Solving A3 Format
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