The 7 step method for Practical Problem Solving skills & the 10 most common mistakes to avoid
Practical Problem Solving models are often shared online BUT the pitfalls are rarely well explained. In this blog we’ll be drawing on our
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+44 (0)1335 347169
Online Practical Problem-Solving Course
Transform your factory's efficiency with practical problem-solving skills that deliver immediate real-world improvements.
✓ Learn as you go, on the shop floor
✓ Access step-by-step guidance from industry experts
✓ Be able to identify which problems to tackle first
✓ Improve skills by up to 50% after just one use
✓ Exceed SQDCPE targets
✓ Gain essential skills for career growth
What is Practical Problem-Solving?
Practical Problem-Solving is a hands-on Lean approach that helps you spot, analyse, and fix issues that get in the way of things like safety, quality, delivery, and cost.
Using simple tools like Fishbone Diagrams and the 5 Whys, this method helps you and the wider team dig into the root cause of problems, frame the problem simply and come up with solutions that last. Here's what you'll develop in the course:
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Problem Identification: Learn to pinpoint specific problem areas through data and team input.
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Root Cause Analysis: Use tools like the 5 Whys and Fishbone Diagrams to get to the core of the issue and solve the real problem, not just the symptoms.
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Actionable Solutions: Create and implement standardised solutions that prevent the issue from happening again, while improving processes over time.
Why is Practical Problem-Solving important?
Practical Problem-Solving is key for any manufacturers that want to hit their strategic and operational goals. It builds a culture of continuous improvement by helping teams solve problems step-by-step and make changes that last.
Address true root causes
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Solve the underlying issues to prevent recurring problems
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Eliminate the guesswork and avoid wasting time and energy on ineffective fixes, ensuring that you're solving the right problem the first time
Improve team collaboration & confidence
Increase operational efficiency
Implement long-lasting solutions
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Give teams the tools and confidence to solve problems
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Streamline processes to reduce delays, waste, and inefficiencies
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Ensure changes stick by creating standard solutions that improve over time
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Build the problem-solving experience that positions you for leadership roles and career growth
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Minimise defects and errors, cutting down on time spent redoing tasks and improving overall efficiency
Get to the root of problems with SempaiGuide
Our courses are all about delivering real, practical results fast.
Through real-world exercises and practical tools, we’ll show you how to identify priority issues on the shop floor, address them quickly, and implement lasting solutions that prevent recurrence.
The course is broken down into 6 bitesize interactive sections, designed to help you to:
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Identify which problems to address first
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Solve these problems efficiently
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Prevent recurrence
This course equips you with the skills to drive continuous improvement and keep your operations running smoothly.
* See case study examples.
Practical Problem-Solving Course Outline
The Practical Problem-Solving course teaches you how to identify key issues in your workplace and solve them efficiently. You’ll dive into real-world factory scenarios, get expert guidance through video tutorials, and take on hands-on tasks right on the shop floor. Plus, you’ll have access to downloadable tools to help you apply what you learn as you go, ensuring problems are solved for good.
It’s designed to fit right into your workday, so you can start, pause, and pick up whenever it works best for you.
01.
Practical Problem-Solving
What’s in it for me?
Bring him home!
02.
Mean or Lean?
Solve a landmark case
Fishbone
How do you stop the seagulls?
5 Why thinking
Thinking is free
Top tips
5 Why on the shopfloor
What to do
03.
Problems at work
Sound familiar?
Treat it like a crime scene
Common pitfall
Why do you need a method?
The 7 step method for practical problem solving
04.
Keeping Track
Case study introduction
At the Canning Factory
Data Analysis
Analyse the data in the table
Analyse the data in the graph
Let your data do the talking
Identify the main concern
Decide what to problem solve
Charts and templates
Problem statement
Before data
What do you mean 'dent'?
Which zone causes the problem
04 cont.
Where's your problem being caused?
Which type of dent?
Pulling things out
Your probable causes
Root causes - The 5 Whys part 1
Your root cause and countermeasure
Running a PDCA trial
What is PDCA?
The 5 Whys part 2
Testing probable causes
Your countermeasure
Repeat to refine
After data
05.
Wrap up
Keep it up
Test that you have found the root cause
Top tips
Summary
A3 summary case study
06.
The End
Take a bow
Certificate
Let us know what you think
SempaiGuide Case Studies
The SempaiGuide Approach
With 25 years of global Lean experience and insights from today’s industry leaders, SempaiGuide courses are crafted to transform your manufacturing operations and equip you with essential skills for career growth.
Learn
with real-world examples
We start with why Practical Problem-Solving is vital and the pains it solves before showing how to do it using simple, practical steps with examples in real factories with real employees.
Track
the impact in real-time
In-situ improvements are captured throughout the course with built-in improvement trackers for quantifiable ROI.
Why choose a Practical Problem-Solving course from Sempai?
100% of team leaders love or like the courses
Based on 50 users across 10 businesses in 5 manufacturing sectors
Immediate, tangible SQDCPE results
Each course features built-in improvement trackers for immediate, quantifiable results aligned to SQDCPE targets
Building the leaders of tomorrow
Each course, fosters a culture of continuous improvement whilst embedding essential skills for career advancement
Lean learning, on the shop floor
We understand that shop floor employees face frequent interruptions, so SempaiGuide courses are designed to seamlessly integrate into the natural flow of the working day on the shop floor.
Improved course engagement
Instant feedback loops provide positive reinforcement, improving course completion rates and scores.
SempaiGuide Plus is a blended offering, giving you access to an annual subscription of Lean courses plus additional virtual support from our team which includes:
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Remote check-ins
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Q&A sessions
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Guidance on a scenario you want to address
Our customers find that regular check-ins and reviews, with targeted support, help to embed lean habits and sustain great results from the team.
Sempai consulting is a truly bespoke option where you can draw heavily on our expertise to work alongside you and your team to tackle a range of projects including:
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Senior management coaching to grow and embed a strong, high performing lean culture throughout your business
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Support for HR with employee development i.e. performance reviews and talent identification at all levels
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Development pathways across all levels in Operations Management, from Operator to Operations Director, Materials Management, Engineering, Quality & Maintenance
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Q. Can I track my/my employee’s progress?A. Yes! You will have a login which provides you an overview of your progress through the course and your score. A certificate is awarded at the end of the course but the focus is centered around the in-built trackers that showcase the real-world results achieved from implementing the 5s principles.
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Q. How much time am I going to have to invest?A. The course length varies but typically takes 10 hours to complete which includes the practical application. The course heavily focuses on the practical application of the 5s skills. We have designed the courses to work alongside you during the normal working day on the shop floor. It is broken down into bitesize sections, with the added option to pause at any point, making it easier to 'pick up and put down' where you left off.
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Q. What if I want additional support?A. SempaiGuide Plus gives you access to the online course plus additional in-person or virtual support from our team of experts. Over the years we have supported organisations and individuals with a vast array of projects from the creation of employee development pathways to ongoing coaching to develop Lean strategy across the business.
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Q. Will it deliver sustainable change?A. Each course is developed using an active learning approach within a 'micro-learning' framework, proven to deliver tangible, long-lasting results. If unsure if this course is right for you, we offer a free trial of one of the course sections.
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Q. What if staff leave the business – will I have to start again?A. Absolutely not! From a practical perspective, if you've purchased a course for several team members and someone leaves, you can easily transfer the course to someone else. When it comes to making changes, a key part of all SempaiGuide courses is demonstrating how to standardise these improvements so they become a natural part of your business workflow. Additionally, embedding Lean principles across your organisation not only improves workflow and safety but also helps reduce staff turnover. By enhancing work-life balance, involving employees in decision-making, and fostering a culture of continuous improvement, Lean practices reduce burnout, increase employee loyalty, and support career development.
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Q. I’m concerned employees just won’t use the course.A. From a study of 50 users across 10 businesses in 5 different sectors, we found a 95% course completion rate, with 100% of team leaders recommending our courses. We offer free demos and trials, so if you're unsure, why not try it out for yourself!
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Q. How does the cost compare to the results achieved?A. Our courses are designed to be flexible, with on-demand courses starting at just £419 with up to 7x ROI achieved often after just one pass of the course. 5s, as part of team leader development, has led to promotion of team leaders to fill the talent pipeline.
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