Problem Solving
Techniques Training
A hands-on training program designed to instil a systematic approach to defining problems correctly, analysing their root causes and developing lasting solutions.
Why Problem Solving Techniques?
Most problems on the shop floor are temporarily suppressed with surface-level measures, but they recur because the root cause is never resolved. Systematic problem solving tools make it possible to diagnose the cause correctly, develop a lasting solution and stop the same fault happening again.
Program Content — Tools & Methods
From problem definition to root cause analysis, and from prioritisation to solution development, the training covers five practical tools — both in theory and through case work — that can be applied directly on the floor.
Problem Definition & Writing It Correctly
Defining the problem correctly is half the solution. Covers how to fix vague, overly broad or symptom-focused definitions.
PDCA — The Plan-Do-Check-Act Cycle
Systematic management of problem solving and improvement actions through the Plan–Do–Check–Act cycle.
Pareto Analysis — The 80/20 Rule
Using data to identify the 20% of problem sources that cause the greatest impact, and directing improvement effort to the right place.
5 Why — Five Whys Analysis
The technique of reaching the true root cause from a surface symptom through successive "why?" questions; its pitfalls and correct use.
Ishikawa — The Fishbone Diagram
The Ishikawa diagram, which visually maps every possible root cause; team-based analysis and category management.
4M Analysis
Comprehensive root cause investigation through the 4M framework, which systematically assesses Machine, Material, Method and Man factors.
Daily Program Flow
The morning block covers the five problem solving techniques with theory and examples; in the afternoon a root cause analysis is carried out on a real shop-floor problem and a lasting solution is developed.
Application & Workshop (13:30 – 16:00)
- Root cause analysis on a real problem
- 5 Why and Ishikawa exercise
- Developing a solution and building an action plan
Problem Definition & PDCA
Covers how to define and write problems correctly, the PDCA cycle and its implementation steps.
Pareto, 5 Why, Ishikawa & 4M
The four analysis tools are covered with examples and case studies; it is made clear which tool to use in which situation.
Root Cause Analysis Workshop
A group-based 5 Why and Ishikawa exercise is run on a real shop-floor problem.
Solution Development & Action Plan
Lasting solution proposals are developed from the root cause findings and an action plan is produced.
By the End of the Training, Participants…
Participants who complete the training address problems at root cause level rather than symptom level, and can choose and apply the right tool to develop a lasting solution.
Being able to define problems correctly
Being able to analyse root causes systematically
Being able to develop lasting solutions
Being able to apply problem solving tools on the shop floor
Who Is This Training For?
Problem Solving Techniques training suits every operations, quality and engineering team that wants to solve recurring shop-floor problems with systematic methods.
Operations Managers
Managers who want to resolve recurring problems at root cause level.
Manufacturing Engineers
Engineers who want to analyse and solve line-related problems with systematic tools.
Quality Engineers & Teams
Quality professionals who want to find the root cause of quality defects and prevent recurrence.
Continuous Improvement Teams
CI professionals who integrate problem solving tools with Kaizen actions.
Consultant & Instructor
With 24 years of automotive experience, Ertuğrul Turgay delivers problem solving techniques in a format grounded in shop-floor cases, focused on tools and geared to lasting behaviour change. Backed by Lean Six Sigma Black Belt expertise, he integrates root cause analysis and quality improvement projects with the WCM methodology.
Request a Quote for Problem Solving Techniques Training
Contact the Opexera team for shop-floor case selection, tool combination and content adaptation tailored to your organisation.