lean problem solving sheet

Lean Events and Training / Forms and Templates

Forms and Templates

Downloads for A3 problem solving, standard work , project management, and value stream mapping .

Problem Solving Templates

A3 Action Plan Form (from Getting the Right Things Done)

• The action plan template helps define the who, what, when, where, and how of a plan on one page.
• Helps track progress and highlight problems so action can be taken.

A3 Status Review Form (from Getting the Right Things Done)

• Top box provides an overview with respect to our critical end-of-pipe metrics.
• Second box provides an overview of activities, and usually reflects what’s been prescribed on the action plan of the right side of the strategy A3.

A3 Strategy Form (from Getting the Right Things Done)

• A strategy A3 is a one-page storyboard on 11-inch by 17-inch paper that helps tell the strategy “story.”
• Logic flows from top left to bottom right, and each box leads to the next one.

Detailed A3 Template (from Managing to Learn)

• Print this A3 template out to remind you of each section of the problem-solving A3 as you are creating your own.

PDSA A3 Template (from On the Mend)

• A3 Template, in Excel, following the PDSA cycle.

Problem Definition Worksheet

• This worksheet can help you breakdown the problem into a clearly defined gap as well as see how the problem aligns to the needs of the business or your True North purpose.

Root Cause Template

• This template gives you space to record the problem as well as the direct causes and underlying causes.

Four Types of Problems

Art Smalley

Managing to Learn: Using the A3 management process

Perfecting Patient Journeys

Beau Keyte , Tom Shuker and Judy Worth

Getting the Right Things Done

Pascal Dennis

Standard Work Templates

Standard Work Operator Balance Chart (OBC)

• The operator balance chart helps create continuous flow in a multi-step, multi-operator process by distributing operator work elements in relation to takt time.

Standard Work Process Study Sheet

• The Process Study Sheet is used to define and record the time for work elements in a process.

Standard Work Production Analysis Board

• A Production Analysis Board is a display that must be located at the exit of the cell (or the line) to show actual performance compared with planned performance on an hourly basis.

Standard Work Skills Training Matrix

• The Skills Training Matrix shows the required and attained skills of every operator.
• The training schedule also should be shown.

Standardized Work Chart

• The standardized work chart shows operator movement and material location in relation to the machine and overall process layout.
• It should show takt time, work sequence, and standard WIP.

Standardized Work Combination Table

• The standardized work combination table shows the combination of manual work time, walk time, and machine processing time for each operation in a production sequence.
• This form is a more precise process design tool than the Operator Balance Chart.
• It can be very helpful to identify the waste of waiting and overburden, and to confirm standard.

Standardized Work Job Instruction Sheet

• The job instruction sheet is used to train new operations.
• It lists the steps of the job, detailing any special knack that may be required to perform the job safely with utmost quality and efficiency.
• It can also be useful for experienced operators to reconfirm the right operations.

Standardized Work Process Capacity Sheet

• The Process Capacity Chart is used to calculate the capacity of each machine to confirm true capacity and to identify and eliminate bottlenecks.
• Processing capacity per shift will be calculated from the available production time, completion time, and tool-change time (and other factors as necessary) for each work piece.

Waste Walk Template (from Perfecting Patient Journeys)

• Taking a “waste walk” is one way to make the waste visible again.
• A waste walk is simply a planned visit to where work is being performed to observe what’s happening and to note the waste. It differs from go-see activities in that you are specifically looking for waste.

Kaizen Express

Toshiko Narusawa and John Shook

Lean Lexicon 5th Edition

Lean Enterprise Institute

Training Within Industry (TWI) Templates and Downloads

8-step TWI problem solving card - as presented by IBM

• 8-steps to problem solving handy pocket card printable.

Solving Problems with TWI

• Solving problems with TWI deployment graphic.

Template of Job Breakdown Sheet

• Job breakdown sheets are created to list the steps and highlight the main factors or key points that go into completing a job.
• It also provides reasons for these key points.

TWI Job Instruction Card

• TWI Job Instruction card in a handy pocket printable.

TWI Job Methods Card

• TWI Job Methods Card in a handy pocket printable.

TWI Job Relations Card

• TWI Job Relations Card in a handy pocket printable.

Lean Solutions

James (Jim) Womack, PhD and Dan Jones

Lean Thinking, 2nd Edition

Project Management Templates

Master Schedule and Action Plan Template for One Goal (from Perfecting Patient Journeys)

• Use this template in your project tracking center so you can track both goals and action items on the same form.

End of Project Review Template (from Perfecting Patient Journeys)

• The following template will help you capture your end-of-project reflections and make decisions about what to do next.

Master Schedule Template (from Perfecting Patient Journeys)

• This template will help you answer this question by letting you include the project goals with space to indicate whether each goal is on track as originally planned and whether the scheduled progress review has taken place.

Team Board Form (from Getting the Right Things Done)

• A team board is a window on both routine and improvement work.
• The board on this template addresses both daily production and strategic issues, and is organized according to SQDCM—safety, quality, delivery, cost, and morale.

Value Proposition Template (from Perfecting Patient Journeys)

• Align the stakeholders around what will be included in addressing the problem,
• Identify the stakeholders who will be added to the project team and actively engaged in creating the current- and future-state value-stream maps,
• Identify additional stakeholders necessary to drive the implementation of the future state,
• Serve as an agreement—a proof of consensus—on the specific problem to be solved, and with the problem statement serve as authorization for the entire project.

Action Planning Template (from Perfecting Patient Journeys)

• Identify the specific changes that need to be made and translate those changes into clearly stated goals and actions (i.e., the means) to achieve those goals.
• Identify the specific methods and action steps you think will help you achieve the goals. These action steps and targets constitute the action plan to achieve a specific goal.

Value-Stream Mapping Templates

Value-stream Mapping Icons for Excel

• At the request of some of our readers we have posted the most commonly used mapping icons so that they can be downloaded for Excel spreadsheets.

Learning to See

Mike Rother and John Shook

VSM Getting Started Set

Lean Enterprise Institute , Mike Rother and John Shook

Mapping to See: Value-Stream Improvement Workshop

Beau Keyte , Jim Luckman , Kirk Paluska , Guy Parsons , John Shook , Tom Shuker and David Verble

Improvement Kata / Coaching Kata

Improvement Kata Learner's Storyboard

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A3 Problem Solving Template

A3 thinking is a logical and structured approach to problem solving adopted by Lean organizations around the world. It can be used for most kinds of problems and in any part of the business. This A3 template uses a four stages model that is based on the PDCA management philosophy. It makes the problem-solving progress visible to the entire team while allowing the lessons to be learned by others.

This template is a Microsoft Excel spreadsheet that you can use and modify to meet your specific requirements. For example, you may expand the implementation or follow-up plans by increasing the number of rows. The template is available in two variations: a user-friendly straightforward version, and a more detailed one that requires providing in-depth information.

A3 Template (32 KB)

A3 Template – Simple (216 KB)

A3 Template – Detailed (340 KB)

Related Templates

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A3: Thinking, Reports, Examples & Templates

A3 thinking.

An Introduction to A3

In the design and construction industry – as in all industries – complex problems arise daily. Each project contains hundreds of decisions containing thousands of variables, and sorting them out to arrive at the best outcome is critical.

A3 problem solving provides teams with a strategy to effectively and efficiently deal with problems that they encounter and decisions that need to be reached. In true Lean fashion, A3 process improvement brings the entire team into the collaborative problem-solving process and allows teams to embrace out-of-the-box solutions.

What is A3?

An A3 is a one-page report prepared on a single 11 x 17 sheet of paper that adheres to the discipline of PDCA thinking as applied to collaborative problem solving, strategy development or reporting. The A3 includes the background, problem statement, analysis, proposed actions, and the expected results.

The History

A3 thinking was developed by Toyota in the 1940s. Toyota believed that any problem should be capable of being explained and solved using one sheet of paper (an 11 x 17 sheet being the largest sized paper that is capable of being faxed and closest in size to the traditional A3). 

The company also believed that if a problem is too complex to fit onto an A3 report, it should be broken down into smaller bits that would be solved individually. If your problem cannot fit onto an A3, you should reconsider the scope of what you are hoping to accomplish.

Who Uses A3 Strategies?

Today, A3 strategies are deployed across various industries that employ Lean thinking such as:

• Design & Construction
• Manufacturing
• Project Management
• Engineering & Architecture
• Service Industries

LCI’s Meaning of A3

A3 thinking is an extremely useful tool when utilized correctly. By distilling the entirety of a problem on a single sheet of paper, A3 Lean thinking forces team members to collaborate and rationalize through the problem solving process. A3 thinking makes for more effective problem solving and produces written explanations that can then be passed on to senior management. An effectively completed A3 report will also build management’s confidence in the team and its ability to solve problems.

A3 Reporting

A well-written A3 report should show and explain the consideration that went into the counter-measure to the problem listed. Properly executed plans include the input of team members from all across the stakeholder spectrum and should allow members to emerge as leaders in its problem solving. A3 papers can also be referenced later, allowing the lessons learned during the process to be shared with future project teams.

Understanding A3 Thinking

A3 thinking does not provide a solution to the problem your team is facing. Rather, it guides your team’s process to help it reach the best possible countermeasure with the tools it has at its disposal.

An A3 report is to be filled out by one person on the team – the “champion” – who will gather assessments and intel from other members in a collaborative fashion. Bringing all of the knowledge and expertise of the team to bear when solving a problem is the best way to come to a satisfying outcome.

Problem Solving: An A3 Process

A3 thinking allows for many different types of decision-making. But ultimately, all decisions are fundamentally a form of problem solving. For example, A3 thinking can be deployed to guide the team in optimizing decisions during the design phase, or for solving a constructability challenge.

The First Step to A3 Thinking

The first step of the A3 process for problem solving is to correctly identify the problem. From unexpected lead times on materials to communication breakdowns among design teams, “problems” are in no short supply in the design and construction industry. Before engaging in A3, ask yourself the following questions about the problem you are working to solve.

Questions to Facilitate the Process

• What are you trying to address or solve?
• What is the current situation?
• What are clear Conditions of Satisfaction (CoS) I can develop?
• Where can I brainstorm and analyze the 5 whys/root cause ideas?
• What’s a recommendation I can put forth?
• What is my plan to implement the recommendation above (if applicable)?

State plan to check and adjust using the PDCA cycle.

More on the PDCA Cycle

PDCA stands for Plan, Do, Check, Adjust. Explore each element of this acronym for more information about how it supports both the problem solving questions above as well as A3 problem solving as a whole.

Identify an issue in your process and exercise continuous improvement by planning your course of change.

Perform your case study by applying the corrective actions outlined in the “plan” stage in an experimental manner.

Follow the performance of your experiment and measure it to determine whether it is having the desired effect.

If your plan worked, implement the change to the necessary areas of your process. If it did not, determine what you will do differently next time and repeat the cycle.

A3 Reports for Solutions

While A3 reports broadly follow the PDCA cycle, the actual journey of an A3 process is a bit more granular. Let’s analyze the various steps and sections of an A3 report.

Describe the problem, theme, or issue. List out all of the details including the champion’s name, date, and the names of all of the collaborators who will be helping with the report.

Establish the business context & importance. Provide additional information on the problem being addressed.

Current State

Describe what is currently known about the problem. Note potential variables and roadblocks that may stop your team from solving this problem and additional information you hope you acquire.

Future State or Goal

Identify the desired outcome for your experiment. Identify the Conditions of Satisfaction (CoS) for the project.

Analyze the situation and underlying cause.

Recommendation

Provide a recommendation for process improvement that your team can implement for the future.

Create a follow-up/review process.

A3 Examples

A3 thinking is frequently applied in Lean design and Lean construction during all phases of the process for the purposes of making sound decisions. In the example below, A3 thinking is applied to the process of learning Lean design and construction techniques.

A3 Template

The Lean Construction Institute seeks to educate companies all throughout the design and construction industry on Lean practices and methods. Here is our A3 template which you can use to guide your decision-making processes.

A3 Training

The Lean Construction Institute offers A3 training as well as tools , events , education , and networking opportunities for Lean practitioners in design and construction all around the world. Whether you’re a Lean expert or are just learning about Lean for the first time, LCI can provide the tools you need for problem solving and continuous improvement in your business.

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A Deep Dive into the A3 Problem-Solving Approach

• 11 mins to read
• June 20, 2023
• By Reagan Pannell

In today’s fast-paced and fiercely competitive business world, organisations must find ways to continuously adapt, evolve, and excel. Amidst the myriad methods and techniques for achieving improvements and driving continuous improvement, few have proven as profound and transformative as Toyota’s A3 problem-solving approach. 

A significant driving force behind the company’s rise to global prominence, the A3 process fosters a culture where problems are embraced as opportunities for growth and learning. In this article, we’ll explore the origins and underlying principles of the A3 approach and uncover the secrets to its success in unlocking the power of improvements.

Understanding the A3 Approach

The A3 methodology is an integral part of the Toyota Production System (TPS), a set of principles and practices that have shaped the company’s approach to manufacturing, management, and continuous improvement over the years. Named after the A3 sheet of paper that was historically used to capture the plan, analysis, and follow-up on a single page, the A3 process represents a simple, yet powerful, tool for addressing complex challenges and discovering lasting solutions.

At its core, the A3 approach is rooted in three key elements:

1. Thorough problem analysis: The foundation of the A3 process lies in digging deep to diagnose the true nature and root cause of an issue, rather than jumping to hastily devised fixes that merely address symptoms.

2. Structured documentation: The A3 report serves as both a communication tool and an iterative planning device, with each section building on the previous ones to guide problem solvers through a comprehensive analysis, solution development, and execution process. It’s the foundation of good continuous improvement.

3. Cyclical learning and improvement: Leadership and employees alike are encouraged to commit to hypothesis-driven inquiry, observation, experimentation, and reflection, leading to a culture that actively seeks and leverages opportunities for growth by solving problems.

How to Implement the A3 Process in Your Organisation

The Lean Thinking A3 approach can be distilled into seven essential steps:

1. Identify the problem: 

Clearly articulate and define the issue at hand, avoiding the temptation to jump to solutions or assume important facts to be self-evident..

When identifying the problem, it is important to ensure that all relevant stakeholders in the organisation are consulted. This helps to ensure that the issue is accurately described and understood from multiple perspectives. A thorough problem analysis should also include conducting research into possible causes or root issues, and clearly documenting any observed symptoms of the problem. Additionally, it is essential to identify any major risks associated with not finding a solution and recognise any constraints (both external and internal) that may exist which could limit potential solutions. Lastly, it is important to consider any potential opportunities which may arise from addressing the issue that may have been overlooked at first glance. This is the problem statement part which is a critical component that identifies the difference between the current condition and the target condition.

At this stage, we are not looking at how to solve problems being faced or at the potential solution to solving problems. It’s about developing a good understanding of how the actual results differ from the expected results and providing an in-depth systematic approach to process improvement and developing problem-solving skills.

2. Establish the context and background: 

Provide a high-level overview of the problem, describing the stakeholders involved, relevant data, and the broader organisational context in which the challenge has arisen..

It is important to ensure that all stakeholders are properly considered when identifying any potential solutions as their perspectives can play a vital role in determining an effective solution. All related data should be thoroughly analysed to understand the full scope of potential solutions. This includes resources, costs, timelines, and any legal or regulatory issues that may need to be considered. Additionally, it is important to consider how well-proposed solutions fit within existing organisational policies and procedures as this could impact implementation success. Finally, understanding how proposed solutions would interact with other initiatives or processes currently taking place in the organisation can help inform decisions about whether or not they are viable options. It may include conducting some value stream mapping to dig deeper into the current state.

It is important to fully explore any underlying factors that may be contributing to the issue at hand and ensure in-depth problem analysis. This includes looking deeper into existing systems, structures, and processes related to the problem in order to identify potential areas of improvement or optimisation. Additionally, it is essential to consider any relevant industry trends or external influences that could impact how the problem manifests within the organisation.

When analysing a problem, collecting data from various sources is important to get a more comprehensive understanding of how a particular issue can be addressed. This includes mapping the current process using the VSM, SIPOC, Process Mapping or Flowcharting techniques. Additionally, interviews and surveys can be conducted with stakeholders to gain insights into how they perceive the issue and their perspectives on potential solutions. Lastly, it is important to observe any real-world activities related to the problem to uncover key areas where time, effort, resources, money etc is being wasted. This is the time improvement that may not have been identified otherwise.

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Get 3-days free access to our green belt course, accelerate your career, 3. set a goal:, now that you have identified the problem and outlined the relevant context, it is time to set a project goal or outcome..

This involves clearly articulating the desired state of affairs and any key deliverables of the proposed solution. Whether it is reducing operational costs, increasing efficiency, improving customer experience, or something else entirely – defining specific objectives with measurable metrics can help ensure that project teams stay focused and remain aligned on their ultimate destination.

At this stage, it is also important to consider how long it will take to reach the desired outcome. Establishing an implementation timeline will help safeguard progress and provide a framework for tracking results along the way. Setting milestones for achieving particular goals at certain points in time can be especially helpful in keeping teams accountable throughout the process. Additionally, having a plan for evaluating success after reaching the end target will allow stakeholders to gain further insights into how effective their approach has been in addressing underlying problems, as well as how well-proposed solutions have fared once implemented.

4. Investigate root causes:

Use a variety of techniques (e.g., the 5 whys, fishbone diagrams, pareto charts) to probe the problem’s underlying causes and avoid settling on proximate reasons..

The process of identifying root causes is essential when using data-driven tools. We always want to find the simplest root cause approach.

One of the most widely used methods for root cause analysis is the ‘5 Whys’ technique. This method involves asking a series of ‘why’ questions to determine the underlying cause of a particular symptom or issue. The goal is to keep asking “Why?” until you reach an answer that can provide insight into how to address the problem and prevent it from occurring in the future.

Another commonly used tool for root cause analysis is the fishbone diagram (also known as Ishikawa diagrams). This approach involves visualising all potential causes which could be causing a symptom or issue in a logical format, allowing users to identify patterns and uncover links between root causes and their respective effects. This technique can be helpful in identifying and focusing on key areas for improvement, as well as helping to identify interdependencies between components within an organisation’s systems.

Finally, Pareto Charts are useful for analysing data collected from surveys, interviews, observations, etc., concerning the severity or frequency of occurrence. This type of chart helps users quickly identify which factors are contributing most significantly towards an issue, allowing them to focus resources towards addressing those areas first and foremost. Additionally, Pareto charts can also be used to prioritise different solutions based on their estimated effectiveness in addressing an issue.

In conclusion, understanding the root cause of an issue through rigorous techniques such as 5 Whys, fishbone diagrams, and Pareto charts provides invaluable insight into how best to address it effectively while preventing it from reoccurring in the future. By leveraging these tools along with other data-led approaches such as process mapping and flowcharting, organisations can ensure that any proposed solutions are well-informed by both qualitative and quantitative data sources as well as ensure they are building consensus across the entire organisation.

5. Countermeasures:

Identify the right countermeasures (corrective actions) to implement that will directly impact the root causes identified..

Brainstorming is a useful tool for identifying potential improvements. It involves coming up with ideas and solutions in an open and collaborative manner, without judgement or criticism. By allowing team members to share their thoughts freely, brainstorming can help uncover innovative solutions that may have otherwise gone unnoticed. Additionally, looking at how waste reduction, flow and pull can be used to improve processes can also provide valuable insights into where improvement opportunities lie.

Brainstorm potential solutions that directly target the root causes and create detailed action plans for implementation, complete with assigned roles, responsibilities, and timelines.

Once the countermeasures are identified, it is important to design an implementation plan and assign roles & responsibilities. This will help ensure that all stakeholders understand their part in the implementation and can work together to achieve the desired outcome. Additionally, it is important to track progress along the way – setting measurable milestones that can be tracked against goals established during the initial problem-solving phase will help keep teams accountable and allow for course corrections if needed.

By utilising A3 Problem Solving Tools such as a template, organisations can easily document and share their analyses with relevant stakeholders throughout each stage of the project. Having detailed record-keeping like this also helps teams stay on target over time while providing insights into how proposed solutions may need to be re-evaluated down the line. This implementation plan provides the entire organisation with a clear project status on a one-page report.

6. Evaluate the results:

Measure the impact of your countermeasures against the problem, using well-defined success criteria, key performance indicators, or other relevant metrics..

Once the countermeasures have been implemented, it is essential to measure and evaluate their success. This can be done by tracking performance against the initial objectives established during the goal phase, as well as establishing key performance indicators to gauge how well the proposed solutions have fared.

Additionally, stakeholders should also consider conducting a post-implementation evaluation in order to assess how successful their approach has been in addressing underlying issues and determining what lessons can be learned from the experience. This will enable teams to identify strengths and weaknesses within their existing processes and make any necessary adjustments going forward. By understanding the outcomes of their improvements, organisations are able to gain valuable insights into how well they’ve succeeded in achieving their goals and ensure continued success moving forward.

Once the countermeasures have been implemented and their success measured, it is important to compare the results against the initial objective. This can be done in a variety of ways, including graphical analysis such as charts, process maps or flow diagrams. Graphical analysis helps to visualise the differences between results achieved before and after the implementation of new measures in a meaningful way. It also provides an increased level of clarity when assessing whether the desired outcomes have been achieved or not.

Process maps can be useful in understanding how changes made during the improvement phase have impacted processes within an organisation. By mapping out existing processes and then comparing them against those following implementation of countermeasures, teams can easily pinpoint where improvements were made and analyse how they led to improved performance overall.

Charts, on the other hand, enable users to quickly identify trends that may have emerged from data collected during the project. For example, if performance metrics are tracked before and after countermeasures are implemented, users can use charts and graphs to more clearly observe any patterns that may indicate an improvement or regression in performance over time – providing further insights into which areas need further attention or adjustment moving forward.

Finally, dashboard views provide an effective means of displaying results at a glance while highlighting any anomalies that might warrant further investigation. Dashboards allow stakeholders to gain access to important information quickly and easily while also helping them keep track of progress towards goals set out during initial problem-solving phases. Additionally, because dashboards support data visualisation capabilities they offer a highly interactive user experience which can help teams understand underlying trends with greater clarity and precision.

7. Standardise and share:

If a countermeasure proves successful, integrate it into the organisation’s standard operating procedures and share it with other teams as a best practice..

Once the countermeasures have been successfully implemented and measured against the initial objectives, these changes need to be integrated into the organisation’s standard operating procedures (SOPs) and shared with other teams as best practices. This will ensure that any improvements made during the problem-solving phase are consistently applied across all teams within the organisation.

In order to ensure that these improvements become part of the organisation’s long-term strategy, process maps should be updated to reflect the new improved way of working. Process maps provide a visual representation of how workflows are structured within an organisation, and by updating them in line with newly-implemented countermeasures, organisations can ensure that their processes continue to remain up-to-date and efficient moving forward. It may also be necessary to build a follow-up plan if not all tasks are fully completed as well as develop a Lean-focused PDCA cycle to ensure long-term effective collaboration on the solutions that were implemented.

Process documentation should also be updated in order to keep track of changes made during problem-solving. By documenting not just the solutions that were proposed but also why they were proposed, teams can gain valuable insights into their decision-making process which they can leverage for similar future problems.

Furthermore, it is important to update key performance indicators (KPIs) to accurately reflect any progress made during problem-solving. By tracking performance against objectives established before and after countermeasures were implemented, organisations will be able to identify any areas that may still need improvement or require further adjustment going forward. Additionally, tracking KPIs over time will help teams understand whether or not their current strategies are leading them towards meeting their goals in a timely manner or if additional measures may need to be taken in order to achieve desired results more quickly.

Finally, organisations should share successful solutions with other teams in order to promote collaboration and knowledge sharing amongst stakeholders throughout different parts of the business. This will allow for ideas generated through one team’s problem-solving efforts to benefit multiple departments – helping foster creativity and innovation while ensuring that everyone is on board with necessary changes being made throughout the organisation. The last step is key to Toyota’s PDCA management system designed for the entire organisation.

By breaking down the problem-solving process into these seven discrete stages, the A3 method offers practitioners a comprehensive, end-to-end framework for tackling complex challenges and driving improvements in any organisation.

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Training the team on A3

To get A3 started, everyone in the entire organisation needs to learn how to use this single-sheet or single-page document. This means training people across all parts of the company so that everyone knows how to use the A3 Problem Solving Tool and A3 template. Training will help make sure that everyone follows a structured approach when using A3.

Getting the organisation fully onboard with A3 Problem Solving is not an easy task and will require a dedicated effort to ensure its successful implementation. To this end, it is important to start with specific areas of the business – whether it be operations, finance or marketing – by setting up targeted training sessions for both operational teams and senior managers. This will help everyone understand how and why A3 is used, as well as the potential benefits it can bring to their business.

Once everyone has mastered the basics of working with an A3 template, companies should look to regularly review and evaluate its effectiveness. This could include setting up quarterly reviews or running workshops where teams discuss successes and areas for improvement when using the A3 tool. Doing this will ensure that any issues are identified early on, allowing the team to quickly adjust accordingly.

At Leanscape, we understand that transitioning to A3 Problem Solving can be a daunting task. With our team of specialists, we can provide your teams with the necessary training and coaching to ensure that they are able to adapt quickly and efficiently. Our comprehensive approach to A3 will equip your team with the knowledge and skills needed to successfully use this powerful tool for improving performance in all areas of your business.

We are committed to helping you develop a culture of continuous improvement within your organisation by teaching best practices and providing guidance through every step of the problem-solving process. Through our specialised training programs, we will help your teams learn how to use the A3 template more effectively, as well as how to interpret data visualisations quickly and accurately – enabling them to take action swiftly when required. Our experienced coaches will also share insights from industry experts on how best to integrate countermeasures into standard operating procedures (SOPs) and process maps, keeping up-to-date with industry trends in order to stay ahead of the competition.

By leveraging Leanscape’s expertise in A3 Problem Solving, you can rest assured knowing that your team is in good hands. Our team is dedicated to providing you with the support needed for successful implementation so that you can achieve sustained performance improvements over time.

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The implementation of A3 Problem Solving provides a comprehensive framework for organisations looking to successfully address complex problems in an efficient and cost-effective manner. By breaking down the problem-solving process into seven distinct stages, users can structure their approach and track the progress of their countermeasures over time.

In order to ensure successful implementation, organisations should dedicate time towards training their teams on how to use the A3 Problem Solving Tool and A3 template. This will give everyone a solid foundation for carrying out future problem-solving activities more effectively, as well as provide insights into the effectiveness of certain countermeasures over time.

Through Leanscape’s specialised training programs, you can ensure that your team is fully equipped with the necessary skills to successfully adopt and incorporate A3 Problem Solving into all areas of your business. Our experienced coaches are committed to helping you develop a culture of continuous improvement within your organisation – providing guidance through every step of the process

Final Thoughts

The A3 approach is an invaluable tool for unlocking the power of improvements within any organisation. By leveraging its structured framework and cyclical learning approach, businesses can remain agile and responsive to ever-changing conditions, allowing them to navigate change more successfully and emerge stronger than ever before. Ultimately, this makes Toyota’s A3 problem-solving process one of the most effective ways to ensure long-term success in today’s fast-paced and competitive market.

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Reagan pannell.

Reagan Pannell is a highly accomplished professional with 15 years of experience in building lean management programs for corporate companies. With his expertise in strategy execution, he has established himself as a trusted advisor for numerous organisations seeking to improve their operational efficiency.

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How to Solve Your Problems With Lean Six Sigma (Free DMAIC Checklist)

Elisabeth Swan is the co-author of “The Problem-Solver’s Toolkit” and co-host of “The Just-in-Time Cafe Podcast.” She’s been a process improvement consultant, speaker, and innovator for over 30 years. She’s the Chief Learning Experience Officer for GoLeanSixSigma.com, a former cast member of ImprovBoston, and – if asked – may still be able to ride a unicycle.

Surgeon Atul Gawande made headlines when he told the world that a simple checklist could drastically reduce unnecessary deaths in The Checklist Manifesto .

Yet, checklists conjure images of forklift drivers on loading docks with clipboards counting boxes. How could they transform healthcare?

“ He has… produced a 90-second checklist which reduced deaths and complications by more than one-third in eight hospitals around the world – at virtually no cost and for almost any operation. ” – James Clarke, reviewing The Checklist Manifesto,  Ulster Med J. 2011 Jan; 80(1): 54.

Aviation was transformed decades earlier when management and engineers at Boeing Corporation created the pre-flight checklist after the 1935 crash of the prototype Boeing B-17 at Wright Field in Dayton, Ohio. Checklists have become so essential to the airline industry that most crashes can be traced to the misuse or failure to complete a checklist.

A New York Times reviewer noted, “no matter how expert you may be, well-designed checklists can improve outcomes”. Since the purpose of process improvement is improving outcomes, Lean Six Sigma and checklists are natural companions.

To prove that, this Process Street blog post will show the relationship between checklists and lean six sigma, and provide you with a free  DMAIC Improvement Project Tollgate Checklist that you can use right now.

Use the links below to jump to that section of the post:

Lean Six Sigma and the role of problem-solving

Lean six sigma & the checklist, introduction phase, define phase, measure phase, analyze phase, improve phase, control phase, checklists and lean six sigma, use process street to reduce error.

Or, if you just want the checklist, check it out below!

Let’s get started.

For those unfamiliar with Lean Six Sigma and process improvement, it is a structured approach for organizations to scrutinize how things are done, poke at data and processes to uncover waste and then cut out things like extra forms, out-dated approvals and other time-wasting steps.

It’s a customer-focused, 5-step problem-solving model that engages entire workforces to constantly seek a better way of doing things.

Proof of Lean Six Sigma’s influence is evident in today’s hiring practices. A poll by GoLeanSixSigma highlights that hiring managers prefer a person who is “ Green Belt Certified ” – having substantial Lean Six Sigma skills – by an almost 80% margin. In an interview with the former head of Twitter, problem-solving emerged as the top skill sought by today’s most influential hiring managers.

In other words, problem-solving (especially via Lean Six Sigma) is an absolutely vital skill.

If problem-solving is a must-have skill and checklists are key to good outcomes, then combining the two makes sense.

DMAIC – Define, Measure, Analyze, Improve & Control – is the 5-Step model for Lean Six Sigma and there’s a set of required tollgates at the end of each phase. These tollgates outline what has to be done in order to move the problem-solving process forward.

Using the tollgates as an outline, we created a dynamic  Process Street template  that you can use for free and run checklists from to track your progress!

Before you can start solving problems, you need a problem to solve.

Picking a process issue – and finding someone in leadership to support you – are two required tasks in this first tollgate. Scoping the project is important (bigger than a “just-do-it” and smaller than “solving world hunger”) but even more critical is finding a Sponsor.

Finding a Sponsor

In a poll asking Lean Six Sigma practitioners what they considered the biggest obstacle to process improvement success, “Getting Leadership Support” accounted for almost a third.

When we coach team leads who tell us they can’t find someone to back their project, we let them know, “No Sponsor, no project”. If nobody in charge has any skin in the game, there’s no point in attempting the process fix. Find a different project that leadership supports.

One thing that helps when searching for leadership backing is being able to explain what Lean Six Sigma is and why it makes a difference. Since the checklist template is dynamic we inserted a video in the Define Phase within the checklist item, “Enlist a Project Champion/Sponsor who will support you and the project”. The team lead can share the video with managers or directors who they consider Sponsor candidates.

There’s also a Project Selection Guide Template embedded in the checklist so users can take a project idea and put it through a few screening questions. Is it a repeating problem? Is there a way to measure it? The checklist serves as a reminder, a source of templates, supporting videos and other just-in-time guidance.

The next set of tollgate tasks cover the Define Phase of DMAIC. This is where problem-solvers clarify the problem, the process impacted and customers of the process.

There is a journey of discovery during this phase as everyone agrees on the issue to solve. One of the big challenges is the tendency of ambitious team leads—or equally ambitious Sponsors—to try to “shoot the moon.”

Shooting the moon

They might want to reduce cycle time, reduce defects , improve margins, and increase customer satisfaction all by next Tuesday. But a project that focuses on everything accomplishes nothing. It’s okay to measure the cost reduction that results from reducing defects. But pick one of those to be the goal. Success is more possible if you focus on one goal at a time .

It takes practice and discipline to develop a manageable goal statement. Another moon shot is aiming for perfection out of the starting gate. When we see a goal statement that claims the team will, “reduce defects from 25% to 0%” then we know there is a sizable risk of failure and disappointment.

That’s why the Define Phase of the checklist includes a Goal Builder Template along with a blog providing tips on how to create well-crafted goal statements.

The primary focus of the Measure Phase is to baseline the process. If you’re trying to reduce defects, you need to know how you’re doing at that now. What’s your track record? You need to know the baseline of the process in order to measure whether or not you made a difference with your improvement when you get to the Improve Phase.

You need to know the gap, so you can close the gap.

The data’s in the system, somewhere…

One of the issues we run into in this phase is problem solvers assuming that data is sitting in a system somewhere waiting to be accessed. If they simply run a report, they’ll have the baseline. Check that off the list. But that rarely goes according to plan.

Maybe there’s system data, but was it entered with care? Is it reliable? We’ve seen teams struggle to use data that didn’t make sense. They could access cycle time data, but it didn’t take into account that the workday ended at 5:00. I had another team looking at why healthcare invoices had to be manually adjusted. They looked up the defect codes and the biggest category was “Other”. System data existed, but it was useless.

Most of the time, it helps to collect some data manually. In order to think through your approach, you need a Data Collection Plan. That involves listing the data you want and considering things like stratification factors—the “who, what, when, where” of data. If you’re looking at defects, should you collect data on defects by product? Defects by the fields on a form? Defects by customer type?

Within the task: “Develop a Data Collection Plan with Operational Definitions and create Check Sheets as Needed”, we’ve embedded a template (The Data Collection Plan) and a video to guide the process.

You’ll learn a lot by collecting the data firsthand, so if the perfect data set is not magically sitting in the system, it helps to have a plan.

Analyze is the crux of the DMAIC method. This is where learners drill down and discover the root cause of the process problem they’ve been chasing. Once you do that, you can solve the problem for good.

But if you have not determined the root cause then you might be solving a “symptom,” putting a bandaid on the problem or implementing a change based on a hunch. All of this means there’s a high likelihood the problem will remain and the efforts will have been in vain.

Finding the smoking gun

If you’ve always been told, “don’t bring me a problem, bring me a solution,” that’s an encouragement to jump right past this step into the fun of solutions. I’ve seen teams go with their assumptions regardless of what the data says or the process analysis reveals. I’ve seen Sponsors who tell teams what solutions they want to be implemented right from the get-go.

How do you stick with analysis long enough to find the smoking gun? The trick is to keep collecting the clues in the Cause & Effect Diagram , aka The “Fishbone Diagram”. It’s an aptly named tool, popularized by Dr. Ishikawa , which resembles a fish skeleton. Its construction allows teams to develop root cause theories around a problem as they build their knowledge of the process.

Each time they collect data, interview process participants on a Gemba Walk or map the process steps, they uncover potential reasons for defects. Making the most of the Fishbone Diagram is key but, during a poll, users reported where they fell short.

Solutions masquerading as problems

Over a third of respondents reported the issues of “listing solutions” on the Fishbone instead of causes. What we hear are phrases like, “the root cause is a lack of training”.

The problem with “lack of” anything is that it’s a sneaky way of putting a solution on the Fishbone.

The question is, “what is the training addressing?” Is it lack of user knowledge? If that’s the problem, could it be solved with helpful visuals, a simpler process? There are a lot of ways to address user knowledge before jumping to more employee training.

This is when you want to behave like the persistent detective – think Columbo, the classic 70’s TV icon. Every question helps you accumulate clues. People working through the process may have the answer without knowing it. The trick is to keep looking upstream until you find potential culprits. Dig past the symptoms.

To help with this phase, the checklist includes both a Fishbone Diagram Template as well as a video on how to get the most out of the Fishbone.

The Improve Phase is a long-anticipated step in the journey. It’s the step teams generally want to jump to from the start. Testing countermeasures, piloting solutions, watching the problem disappear, that’s the fun of process improvement. If you’ve done a proper job of Define, Measure, and Analyze, this phase falls nicely into place.

The ripple effect

The catch? Unintended consequences.

If you toss a stone into a lake you can see the ripples flow out from the center. The same principle holds true for process change. If you remove a step, change a form, skip an approval , will things fall apart? For that, we look to the Failure Modes & Effects Analysis or FMEA for short.

It’s a methodical way of assessing the potential for things to go wrong. It Involves deciding the potential severity and frequency of future problems and then mistake-proofing the process to prevent them. The technique originated at NASA since they couldn’t risk trial and error when sending men to the moon. By thinking through the risks of change they developed the kind of contingency plans you saw on display in movies like Apollo 13.

That’s why there’s an FMEA Template and a video on how to use it tucked into the main checklist from this post.

It’s okay to make changes. It’s simply key to think through the impact of those changes on other parts of the business.

Process Improvement can happen quickly and have a dramatic impact, but it’s critical to “stick the landing.” The Control Phase exists to see the improvement through to stability.

If teams move on and everyone takes their eyes off the ball, things may start to slip. What they need is the ability to continuously see the performance of the new process.

Sticking the landing

Have you ever tried to watch a game without a scoreboard? How would you know who was winning? Or how much time was left?

It’s the same with process work.

How does your team know how they’re doing? How do you stay aware of how the new process is performing?

By making the data visible.

Keeping an eye on Process Performance can be done with a single metric — you need to focus on one thing. If the goal was to reduce defects, then the single metric would be tracking the daily percentage of defects. A great way to measure success is with a Control Chart.

Control Charts are time charts. You might know them as Line Charts or Run Charts. They include a measure of variation so they are often referred to as “Run Charts that went to college”. They can be created in Excel , but they can also be drawn by hand.

Teams often set up whiteboards in the shared workspace to track things like defects. People can rotate responsibility for updating the chart. If people can see the measure and are responsible for it—they pay attention to it. What gets measured gets managed.

The Control Chart Template is embedded in the checklist for the Control Phase.

Process Improvement is a mainstay of Operational Excellence and checklists are simple but effective ways to make sure you get the outcomes you want. The following quote comes from the interim CEO/President of the Association for Manufacturing Excellence ( AME ).

“ I am a big fan of checklists for ensuring quality at the source. They serve an important purpose in reminding us of all that’s needed in a particular process or project. Without checklists, we risk missing or overlooking something by mistake. Checklists work best when ticking off items as they are completed, not en masse once the entire project is done. The key point is to use and follow them, not “pencil-whip” them from memory after the fact. While not foolproof, checklists can help us cover the details and result in more thorough, successful improvement efforts. ” – Jerry Wright , President, AME

Checklists have transformed healthcare, aviation, and countless other industries. Run this Process Street DMAIC Tollgate Checklist and make sure your next improvement effort gets great results.

Process Street is a powerful piece of workflow software that lets you crush the human error in your organization.

By creating process templates (like the free DMAIC checklist in this post) you can give your whole team a central location for them to see what they have to do, and how exactly they should do it.

No more confusion, no more errors.

Take advantage of our powerful feature set to create superpowered checklists, including:

• Form fields
• Conditional logic
• Variable user permission levels
• Exporting and printing templates
• And much, much more!

Check out our intro webinar to see the app in action!

Stop leaving the success of your processes up to chance. Get started with a free trial of Process Street today!

How do you manage quality control in your business? Let us know in the comments!

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Ben Mulholland

Ben Mulholland is an Editor at Process Street , and winds down with a casual article or two on Mulholland Writing . Find him on Twitter here .

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• The A3 Report – Part 1: Basics

Why the Shop Floor?

Obviously, that is where the real situation takes place. Only on the shop floor can you observe the real situation. If you use primarily reports and presentations, you will get a filtered opinion on the situation – usually in a way that makes the presenter look good. See also my post Visit the Shop Floor or Your People Will Fool You! – Genchi Genbutsu!

Of course, you could observe the shop floor (or wherever your action happens) and then go back to the computer to add the data. However, while walking back and forth, you are likely to forget details of what you have seen on the way. You may also get distracted. It is also a waste of time walking back and forth repeatedly. Finally, due to the walking distance, you may be inclined to make the document in one go. However, I am a strong believer of iterations and changes to work my way toward an improved (not perfect!) situation. This brings me to my next point:

Why Pencil?

Using pencil has lots of advantages. Most importantly, it makes it easy to change the content by using an eraser. Therefore, there is much less of a mental barrier to change the document. With a pen, you will have the subtle pressure to make it correct in the very first try – which usually does not happen.

Another advantage of the pencil is that it is easy to do. While you can change computer documents, it actually uses a lot of your mental capacity merely to operate the software. Doing a sketch by hand is much easier and faster – and can also easily be done on the shop floor. Yet, if you do an image search for A3 report on Google , almost all are clearly done on a computer 🙁 . For more on the advantages of a pencil, see my last week’s blog post On the Benefits of a Pencil in Lean .

Why One Sheet of Paper?

You are all familiar with stacks of paper. To add more information to a document, you merely add more pages to the stack. This works fine with printouts. However, going through that stack is more cumbersome than having one sheet of paper.

Especially if you are on the shop floor, working with multiple sheets of paper is a pain. Believe me, I have tried. Additionally, if you are working as a small team of two or more people, you can look only at the page that is at the moment on top. If you have only one page, then others can see all the data right away, without asking you to flip to another page.

The idea to fit all information related to one project/problem on one sheet of paper dates back to quality guru Joseph Juran (1904–2008). He was very influential in Japan, possibly even more so than the better known William Edwards Deming (1900–1993). Juran guided Toyota toward using one sheet of paper for problem solving, which then was improved at Toyota to the A3 report.

A0, A1, A2, A3, A4, and so on are part of the ISO 216 standard for paper sizes. All of these paper sizes have the same aspect ratio of \[\frac { 1}{ \sqrt{2}}\] , which means that simply by cutting the page in half you arrive at the next paper size. They were originally developed during the French Revolution, and are now used worldwide – with the exception of the United States, Canada, and Mexico.

In the United States, Canada, the Philippines, and in Chile, the U.S. paper sizes are common. Mexico seems to use both standards. The U.S. system is somewhat less structured compared to the rest-of-world ISO standard. For someone traveling between both worlds, the difference in standards always turns out to be a hassle.

In any case, the most commonly used size in (non-U.S.) offices is the A4 paper size (210 × 297 mm or 8.27 × 11.7 inch), which is similar to the U.S. letter size. Probably over 90% of the paper used in a typical (non-U.S.) office is A4 size.

However, Japanese engineers trying to get an overview of a problem on the shop floor quickly found out that an A4 sheet of paper is simply too small to fit all the information. While it is very practical to use, it just was not big enough to give an overview of the entire problem.

Hence, they doubled the size and used A3 sheets of paper (297 × 420mm or 11.7 × 16.5 inch), which is also still commonly found in most offices. The A3 size is somewhat similar to the U.S. ledger or tabloid size.

Please note that some sources say that A3 was the largest size that fit in a fax machine, although most faxes can do only the smaller A4, and special faxes can do even larger than A3 format. Additionally, the A3 report was developed after World War II, but the first fax was developed only in 1974. In any case, now the page was large enough to fit all the information related to the problem at hand.

The next even larger A2 size (420 × 594 mm or 16.5 × 23.4 inch) could fit even more data. The A2 could easily be used in the office where you placed it on a a table. However, the idea is to bring the sheet along with you on the shop floor. And remember, the shop floor is the only place where you get an unfiltered version of the real situation. See my post Visit the Shop Floor or Your People Will Fool You! – Genchi Genbutsu . While an A3-sized clipboard is manageable, an A2-sized clipboard is just too much to carry around.

Overall, the A3 report is one sheet of A3 paper, written in pencil, that is created on the shop floor! This makes it more likely (but, of course, by no means certain) that you will get a representation of the actual situation and a workable solution to your problem through multiple iterations.

You may have noted that the above does not (yet) talk about what actually goes in the report. Well, for me, the conditions above are quite important. Hence, I focused my first post on A3 reports on these four factors. But fear not, in my next post I will go into more detail on what an A3 report actually contains. In the meantime, go out (preferably on the shop floor with a pencil and a single sheet of A3 paper) and organize your industry!

Series Overview

• The A3 Report – Part 2: Content
• The A3 Report – Part 3: Limitations and Common Mistakes

Roser, Christoph. “ Der A3-Report: Mehr Als Nur Eine Problemlösungsmethode .” Yokoten 5, no. 3 (2016).

8 thoughts on “The A3 Report – Part 1: Basics”

I would like to add some of the disadvantages of using pencil: 1. Your writing might not be easy to read by others 2. Changing a number in an Excel cell does not require special expertise 3. Soft copy documents can easily be shared with other people even in remote locations in order to validate them or obtain additional inputs 4. You can keep historic files of documents which have had many updates enabling you to go back to previous versions 5. The work gathered in a pencil file might not be accessible when you look at the same problem at a later stage so you might have to do it all over again

Hi Cornelio, Your points are valid. I write a bit more about it in the 3rd post in this series, and why I think paper is still better. If the goal is to show your work to many other people, then computer may be better. If your goal is to actually solve the problem, pencil may be better. It all depends on what your boss wants from you.

Hi Christoph,

Have you published the follow up posts regarding A3 and if so where can I find them? Regards Chris

Hi Chris, Number two will be on Tuesday Noon after Easter (29th of March), and number three will be on Tuesday noon a week later (5th of April).

Value Stream Maps start out with pencil and paper as well. Clean rooms however need audio and video and tablet tools. Permissions from HR, supervision or union stewards sre good ideas in any case.

Hi Michael, yes, clean rooms have some different rules (do not do a literal “ chalk circle ” in a clean room 🙂 . And it is always helpful to talk with HR before measuring shop floors. In Germany you often even need permissions.

The A3-sized clipboard is manageable, an A2-sized clipboard is just too much to carry around.

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Free Problem Statement Templates: All Formats

By Kate Eby | March 4, 2024

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We've collected the top problem statement templates to help you identify and articulate challenges clearly and concisely in any business context. Download any of these free templates that align with your needs, and customize it for your organization.

On this page, you’ll find a  customer problem statement template , a  problem and solution slide template , a  problem statement document template , and more. You’ll also find information on different  types of problem statement templates and related  problem-solving tools .

5 Ws Problem Statement Template

Download a 5 Ws Problem Statement Template for

Microsoft Word | Adobe PDF | PowerPoint | Google Slides

When to Use This Template:  Use this 5 Ws problem statement template to create a methodical breakdown of issues at team meetings or brainstorming sessions. Ensure that nothing is overlooked by answering who, what, when, where, and why questions about a problem. By doing so, you can create a clear and concise problem statement.

Notable Template Features: Using five key questions to explore a problem fosters a comprehensive understanding of the issue while helping to narrow the focus of your final problem statement. Each segment of the template is color-coded and provides bullet points to delve into specifics, such as who is affected and the problem's scope and significance.

Customer Problem Statement Template

Download a Customer Problem Statement Template for

When to Use This Template:  This template provides a structured approach to translating client issues into an effective problem statement. It is especially useful for customer experience teams, marketing personnel, and product developers who are tasked with turning customer feedback into actionable insights.

Notable Template Features: This template takes you through the steps of clarifying customer issues and perspectives to help teams find customer-focused solutions. Download the template in PowerPoint or Google Slides  for presentations, or try the Microsoft Word or Adobe PDF versions to create a printable worksheet.

Three-Part Problem Statement Slide Template

Download a Three-Part Problem Statement Slide Template for

PowerPoint | Google Slides

When to Use This Template: Use this slide template to present key points to stakeholders in project reviews or strategic planning sessions. Teams can also use this template to facilitate problem-solving meetings.

Notable Template Features:  This template guides the audience from problem to solution to result, promoting a thorough understanding of the problem’s context. Each section includes bullet points to organize and present complex details in a simple yet engaging format.

Single-Problem Statement and Solution Slide Template

Download a Single-Problem Statement and Solution Slide Template for

When to Use This Template: This problem statement slide template allows you to clearly outline a problem and propose a viable solution in one visually dynamic slide, making it a perfect addition to business proposals, project pitches, and strategy meetings.

Notable Template Features:  This slide template separates the problem on the left from the solution on the right, using a clear layout and colorful symbols to grab the viewer's attention. This simple design ensures that the audience grasps the core issue quickly, facilitating a focused and efficient discussion.

For more slide template resources like this one, see this collection of free  PowerPoint problem statement templates .

Project Problem Statement Document Template

Download a Project Problem Statement Document Template for

Microsoft Word | Adobe PDF

When to Use This Template: Use this document template to draft a comprehensive problem statement report. The template is best for individuals or teams tasked with in-depth analysis and documentation of business issues, ensuring that they cover all relevant aspects of the problem.

Notable Template Features: This template features a structured outline with labeled sections for documenting the problem statement, background information, impact, and potential solutions. The outline takes readers through a logical progression — from identifying the problem to proposing solutions — for a clear and persuasive presentation.

Problem Statement Worksheet Template

Download a Problem Statement Worksheet Template for

Excel | Microsoft Word | Adobe PDF

When to Use This Template:  Use this worksheet to create an effective problem statement when starting a new project. The template is particularly useful for project teams that need to align on the specifics of a problem, set measurable goals, and identify obstacles and solutions.

Notable Template Features:  This problem statement worksheet guides you through a step-by-step process to craft a concise and impactful problem statement. The template includes clear sections where you can provide details about the problem, the gap between the current state and the goal, and the people or processes affected. It includes space for setting SMART goals related to the problem, identifying barriers, and formulating a plan to overcome these challenges.

Problem Statement Matrix Template

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When to Use This Template:  This template helps teams and managers prioritize multiple problems. Teams can assess and sort problems based on urgency and potential impact to effectively guide strategic action plans. 

Notable Template Features:  This template organizes essential aspects of each problem into a simple matrix, including a problem statement, priority, visibility, impact, response timeframe, and proposed solutions. The matrix format is useful when you want an overview of problems with key details highlighted.

Types of Problem Statement Templates

Problem statements are used in business settings and academic research to clearly define a problem that needs to be solved. A well-written statement is concise, narrow in focus, and based on evidence. While all problem statements include similar elements, they will vary depending on the context and type of issue. There are many tools that can aid in this process. 

Here’s a closer look at the different types of problem statement templates for project and product management:

Customer Problem Statement Templates

Customer problem statement templates guide you through the process of viewing issues from the customer’s perspective. They provide a structured approach to mapping out the customer journey, pinpointing the underlying cause of problems, and understanding their emotional impacts on customers.

Customer problem statement templates typically organize information into five key elements:  

• I Am: Who is the customer? This could be as broad as a demographic group or as specific as a user persona. Clearly defining your customer sets the foundation for a more targeted analysis.
• I Am Trying To: What is the customer trying to achieve? Articulate the customer's goal or what they hope to accomplish with your product or service. This helps in aligning your solutions with customer needs.
• But: What is getting in their way? Identify the challenges that prevent the customer from achieving their goals. These could be related to product features, service limitations, or external factors.
• Because: What is the root of the issue? Analyze the internal and external factors that contribute to the problem to uncover the underlying causes.
• Which Makes Me Feel: What is the customer's emotional response to this issue? Emotions can affect how customers perceive your product or service. If they're feeling frustration, disappointment, or confusion, they might be less likely to engage positively with your brand or recommend your services to others. Knowing this helps convey the urgency of addressing the problem.

Using a customer problem statement template shifts the focus from internal perceptions of what the problem might be to a clearer understanding of the customer's experience. The process involves gathering and analyzing customer feedback, conducting market research, and possibly engaging directly with customers through interviews or surveys. 

Product Problem Statement Templates

Since having a customer-centric perspective is vital for developing successful products, there is overlap between product and customer problem statement templates. However, understanding customer issues is just one step in the development process. Product teams must consider whether the solutions they come up with will truly benefit the customer, what value a product will bring to the company, what steps are needed to solve the problem, and how to measure success. 

One common structure for product problem statement templates is the 5 Ws framework, which involves answering the following questions:  

• Who: Who is the problem affecting?
• What: What is the unmet need?
• When: When is the problem happening?
• Where: Where is the problem occurring?
• Why: Why is this worth solving?

Some templates might include a sixth question: How are you going to solve the problem?

These templates can help teams identify initial product opportunities, refine product concepts, and diagnose issues in existing products. They help in prioritizing features, making strategic adjustments, and communicating the product vision and challenges internally.

Project Problem Statement Templates

Similar to customer and product templates, project problem statement templates help teams articulate the core issue they aim to address with their project. They are often used at early planning stages to gain clarity and consensus among stakeholders on the project's direction.

A project problem statement template typically includes the following elements:  

• Problem: Clearly define the issue at hand with a precise description of the gap between the current state and the desired state.
• Background: Provide context for the problem by offering insights into its origins and scope. This helps stakeholders understand the complexity and nuances of the issue.
• Relevance: Highlight the significance of the problem, its potential impacts, and why addressing it matters to the organization or stakeholders.
• Objectives: Outline the objectives of the project with SMART goals that guide the project's direction and help in measuring its success.  

Some templates, such as a problem statement worksheet, are designed to help you craft an effective statement, while others are suitable for presentations or reports to stakeholders. For some helpful options, see this collection of free  problem statement slide templates .

Related Problem-Solving Templates

Fully understanding a problem and finding effective solutions requires in-depth analysis. Here is a list of problem-solving templates that can help with that process:

Fishbone Diagram Template

A  fishbone diagram template organizes the causes of a problem into categories, enabling teams to identify, analyze, and address root causes by branching out possible contributing factors from a central problem statement.

8D Report Template

An  8D report template guides teams through a structured eight-step process to identify, correct, and eliminate recurring problems. This problem-solving approach emphasizes root cause analysis and long-term solutions.

A3 Template

An  A3 template offers a concise framework for problem solving, encouraging teams to identify issues, find root causes, and develop solutions on a single A3-sized sheet of paper for clarity and efficiency.

Simple Root Cause Analysis Template

Use our  simple root cause analysis template to map out symptoms, effects, causes, and suggested solutions in a color-coded spreadsheet. Each section includes important details, such as urgency, risks, and success criteria for a systematic approach to analyzing problems.

DMAIC Root Cause Analysis Template

A  DMAIC analysis template outlines a structured, five-phase approach to problem solving

— define, measure, analyze, improve, control — guiding teams through a detailed process to identify problems, analyze causes, and improve processes.

For more problem-solving templates, see this collection of free  root cause analysis templates and  Lean Six Sigma templates .

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• A3 Problem-Solving: Fight the Root Cause

The A3 problem-solving tool is a bright example of how problems should be treated to be eliminated efficiently. Scroll down to learn more about A3 and how to use it.

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5 Whys: The Ultimate Root Cause Analysis Tool

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A great part of our daily work routine is actually related to solving problems. Either small or big, problems are an inevitable part of our workday. However, if you decide to act fast and remove a problem as swiftly as possible, you may face the same issue repeatedly.

Instead of fighting only the symptoms, you need to dig deeper and discover the root cause. By doing so, you will be able to protect the work process from recurring problems. This is where the A3 methodology comes into play.

Implementing an A3 problem-solving tool is a bright example of how problems should be treated to be eliminated efficiently. Based on some simple steps and ideas, the model gives directions on dealing with problem-solving issues through simple structuring, good collaboration, and active communication.

What Is A3 Thinking?

First of all, let’s briefly touch upon the mindset that A3 thinking aims to develop. It can be summarized in 7 elements:

• Logical Thinking – A3 represents a step-based thinking process.
• Objectively presenting information – there are no hidden agendas here.
• Results and Processes – sharing what end results were achieved as well as the means of achieving them.
• Sharing only essential information and putting it into a visual format whenever possible.
• Whatever actions are taken, they must be aligned with the company’s strategy and objectives.
• The focus is on developing a consistent perspective that can be adapted across the entire organization.
• Developing a structured approach to problem-solving.

Origin of the A3 Problem-Solving Tool

The A3 report is one of the many Lean management tools developed as part of the Toyota Production System (TPS).

There isn’t a single inventor of the A3 reporting method. In fact, Isao Kato (former manager at Toyota) describes it as a hybrid between the PDCA cycle and Toyota’s philosophy to make things visible.

There is also a legend that Taiichi Ohno often refused to read further than the first page of any written report. This is why the A3 is a one-page report.

The name A3 comes from the European A3 paper size corresponding to 11-inches by 17-inches or 29.7cm x 42cm.

A3 thinking played a major role in Toyota’s commercial success. Consequently, it became a widespread tool, now used in various industries.

Let’s explore the A3 problem-solving tool in detail.

Foundations of the A3 model

Actually, A3 is just a single report that will not help you solve problems like a magic wand. It is much more important for all involved parties to be dedicated to the process and communicate actively.

Before you begin with the formation of your own A3 reporting method, you need to be familiar that there are 3 major roles in the process:

• Mentor/coach

The owner is responsible for managing the process and maintaining the document. On the other hand, the owner needs to be advised and supervised by a mentor experienced in problem-solving.

The mentor’s role is to give directions and provoke the problem owner to find the solution, but not to give answers and propositions.

Last but not least, there are responders or stakeholders. They are the third party, which is directly interested in the final results of the A3 project.

Here is the challenge. Usually, there is a wide variety of stakeholders involved. The problem owner needs to have access to all of them if needed.

However, we all know that it is a bit difficult to reach higher management in organizations with a strict hierarchy.

This is why the whole organization should be familiar with the concept of lean thinking and be prepared to assists at any time. Sometimes this is challenging, but it can show how flexible an organization really is.

At the end of the day, the active communication between all parties involved is crucial for the success of any A3 project.

The A3 Report

The A3 report is a single-page document, which reflects the results of the whole process. Usually, it contains seven steps, but it may also have other variations. Below you can find an A3 report example, which most often will include the following steps:

• Background/Clarify the problem

Current situation

Set targets/goals, root cause analysis, countermeasures.

• Implementation
• Effect confirmation/Follow-up

The A3 Process

The A3 methodology is a lean thinking process where the problem owner should go through the model's different steps until there is a proper solution to be implemented. The owner needs to communicate actively with his colleagues and the mentor of the project.

Let’s now examine the different steps that comprise the A3 process.

First of all, you need to clarify the problem and briefly describe it. This is a starting point where the owner can add context and support the next steps.

Before a problem can be addressed properly, the problem owner needs to describe the current situation in the area where the issue appears.

At this stage, you can map the different processes that exist around the problem area. It will allow you to see the bigger picture and identify the root cause.

After the current situation is clear, you need to set goals. Keep in mind that at this stage, you need to take into consideration that you don’t have  the full picture .

So after you go through the remaining steps until “effect confirmation,” you can come back to this step and add more details to the initial goals.

This is a significant step from the successful implementation of the A3 process. Trying to fight the problem immediately means that you are only treating the symptoms while leaving the root cause untouched. This way, a problem may appear regularly in bigger proportions.

Therefore, once you have a good understanding of how the processes work and the initial goal, you need to figure out the root cause of the problem. For this purpose, you can use different techniques such as  the 5 whys .

Once you are familiar with the root cause, you may start offering solutions. From here, you can go back to the initial goal and add more details. In all cases, the countermeasures should lead to a clear understanding of how the initial goal will be achieved.

Implementation Plan

After setting the countermeasures, you have to present an implementation plan that includes a list of the actions that will be applied to get the countermeasures in place. It is also helpful to assign responsible individuals for each task and a due date.

Effect confirmation & Follow-up

The last step is crucial for establishing a culture of continuous improvement . It is imperative to measure the actual results and confirm the effect of your countermeasures.

Whether there are positive or negative results, you need to take action.

If the actual results differ from the predicted ones, you should modify the plan, re-implement it, and follow up.

If there is a positive effect, you should communicate improvements to the rest of the organization and ultimately make them a standard.

Benefits of A3 Problem-Solving

The A3 model is consistent, and it encourages mentoring and overall collaboration.

Furthermore, it promotes the cross-organizational sharing of information and encourages learning and continuous improvement on every organizational level.

Also, the A3 methodology encourages commitment to common goals and strengthens the levels of responsibility.

Last but not least, you can use an A3 report not only for problem-solving but also for proposing improvements, reporting, coaching, and others.

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A3 is a useful problem-solving tool that has some significant advantages:

• It is simple and promotes mentoring and collaboration.
• It fights the root cause, but not only the symptoms.
• It encourages cross-organizational knowledge sharing.
• You can use the A3 report for several other things, including reporting, coaching, proposing improvements, etc.

Nikolay Tsonev

Product Marketing | PMI Agile | SAFe Agilist certified

Nick is passionate about product marketing and business development and is a subject matter expert at Businessmap. With expertise in OKRs, strategy execution, Agile, and Kanban, he continues to drive his interest in continuous improvement. Nick is a PMI Agile and SAFe Agilist certified practitioner.

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What is A3 Problem Solving?

A3 problem solving is a Lean approach to reporting issues and presenting ways of addressing them. The simple method, developed by Toyota, bases on documenting a problem, together with its current outcome and a suggested change, on a single sheet of A3 paper (420x297mm), giving it the name. You can use it to make a process change proposal, report on project status, or solve a problem.

A3 takes from the Plan-Do-Check-Act cycle . Though it appears to be a step-by-step process, the method tends to be used iteratively, with the problem and solution sections being cyclically updated.

Taiichi Ōno of Toyota was known for not appreciating reports longer than one page, which helped the proliferation of the A3 approach within the automotive giant’s offices. A3 is similar to the 8D report also widespread in the automotive industry, though typically for complaints management. Furthermore, the ability to quickly discern a problem and understand its solution is innate to Lean values.

Lean emphasizes visualization, with examples in value stream mapping and Kanban’s visual workflows. That made a single-page report presenting what is going on was a welcome addition to a Lean operation.

Through shared use of A3s to solve all problems and plan initiatives, companies can start to operate an A3 system thinking methodology: address difficulties, suggest change, innovate, and curate logical reasoning rooted in the current needs.

Why use the A3 approach to solving problems?

Lean provides a competitive advantage, strategic and operational benefits through its objective to increase the value delivered to the customer and to reduce waste. Engaging in a process that allows the team to find the correct, best solution in the shortest possible time is highly beneficial.

Understandably, some reports and proposals must contain extensive amounts of data, and they have their place in a business environment. But imagine the value and advantage that distilling this information to 1 page has. Consider how much faster decisions can be made based on that. Besides the time savings, the opportunity to use the systematic approach of PDCA supplements the problem-solving skills required to propose accurate solutions.

In preparing for battle I have always found that plans are useless, but planning is indispensable. Dwight Eisenhower

It’s the act of planning that is important, as it spells out all known obstacles, visualizes the action plan, and helps to foresee potential outcomes and issues along the way. While documenting your problem on an A3 piece of paper may or may not yield benefits, the act of implementing A3 thinking is what makes the difference.

The benefits of using A3 thinking are:

• Quicker problem solving through logical reasoning and application of a step-by-step, visual process. Demanding a root cause identification ensures that difficulties are dealt with, not just temporarily masked.
• Easier planning thanks to the application of objective, critical thinking promoted by the A3’s structure.
• Team development through repeated use of a structural tool to find root causes of problems and their best solutions. The use of one tool across all company levels also promotes cross-department collaboration and knowledge sharing.
• Company growth A3 reports help maintain and keep company knowledge on record, helping to sustain good operating policies and build a strong growth culture rooted in solving a company’s actual problems, not abstract ideas.

How to create an A3 report?

Step 1: The title

It should focus on the problem you are trying to solve and not the solution you want to convey. Examples of titles are: “Decrease Team Misunderstanding of Task Instructions” or “Reduce Customer Complaints with Product XYZ” .

Step 2: Background

According to the authors of “Understanding A3 Thinking: A Critical Component of Toyota’s PDCA Management System” , one of the main strengths of Toyota is that they place importance on understanding a problem. Rather than rush onto a solution, Toyota takes the time to precisely understand what is going on. The principle of going on a Gemba walk attests to this need to perceive problems first-hand.

The report’s background section conveys important related facts and how the problem aligns with the company’s strategic objectives. Presenting this right there on the page helps minimize the cost that a board of highly paid executives would need to spend looking at a problem, without a guarantee of them understanding it, nor coming up with the right solution. Consider this checklist for your background section:

• Do I know the needs of my report’s audience?
• Have I provided enough context?
• Does what it presents align with the audience’s strategic goals?
• Can the background be explained in 30 seconds?

Step 3: Current condition

A correct definition and a good understanding of the problem is your path to finding the right solution. That makes working on defining the current condition 90 % of the A3 effort.

The objective here is to make sure everyone is aware of the problem, whether the report documents it appropriately, and whether anyone questions the report’s findings. The use of graphs, charts, or other visual aids is beneficial.

Step 4: Goal

Your target - if you hit it, you know that your problem-solving effort has been a success. But you need to know what metrics will measure success and what the definition of success is. An example could be “reducing customer complaints by 15%, as measured by call center statistics” .

Step 5: The root cause

The focus of the root cause section should be to differentiate between facts and opinions regarding a problem’s cause and effect. You can include your findings from 5 Whys exercises , an Ishikawa diagram , or any other result of your RCA efforts . If the root cause is not defined correctly, the problem will likely resurface, causing waste and negating the Lean principles.

Step 6: Countermeasures

The countermeasures should be the corrective actions to take for the root cause of the problem to be resolved. If not possible - without a process overhaul - you can use containment actions instead to stop the issue from directly impacting the customer. It is OK to address complex problems iteratively, along with the values of continuous improvement .

The section may include a table of the problem causes, actions taken, action owners, and the achieved results.

Step 7: Effect confirmation

Since the A3 exercise bases on the PDCA cycle, this section of your report should show the effort you expended to confirm your findings. The proof that you have indeed solved the problem. For example, software engineers include samples that replicate the bugs and verify they are no longer present after a fix.

If the exercise has not taken place yet, i.e., when you’re presenting a plan to gain approval, you should outline what exercises you will conduct to check if the aim is successful.

Step 8: Follow up actions

The final section should include any other actions that you might want to consider. A principle worth adhering to here is the “Shitsuke - sustain” step of the 5S plan . Consider what you should do to ensure the benefits of this exercise are maintained. And could they possibly be translated to other areas of the company?

An A3 problem-solving report will help you deliver information in a way that provides instant value and can quickly reduce waste.

The most important thing to remember is that the act of Lean problem solving is more important than creating an A3 document that may contain no valid data and be simply a tick on some corporate checklist.

The same is true of all Lean methods and tools - their application alone will not make your company Lean. To truly implement Lean principles, your company culture, thinking, and planning all have to transform.

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Practical Problem Solving (3C & 5Why)

Next to improving the flow of goods and services in a value stream, Lean also focusses on improving the flow of problems ( Ballé & Ballé, 2012 ). Problems are documented and solved on the team board and escalated to a higher level Team board when the team is not able to solve the problem themselves ( Mann, 2005 ). But how do you really solve a problem? This article describes the practice of root cause analysis and the link between the root cause analysis, team boards and the kaizen loop .

The first step in understanding the problem solving methodology, it is important to understand the 3C METHOD , which is used to document and problems and actions on the Team boards (see illustration 1)   

Illustration 1: Example of a 3C template

The 3C ´s stand for Concern, Cause and Countermeasure and encourage employees to think about the definitions of each of these steps. The owner and the date the countermeasure should be implemented are also documented. The Kaizen column is used to evaluate your countermeasure. Is it a fire fighting ´back to standard´ solution or a real preventative ´raise the standard´ solution? If it is a raise the standard solution, the kind of improvements we are looking for within the Lean philosophy, the improvement of the standard should be documented on the kaizen and the kaizen number can be put on the 3C. Finally, the 3C includes a PDCA circle, to be able to track the status of the problem in all stages of problem solving.

Lean puts focus on continuously improving standards, on kaizen, and it is therefore the goal to have as many 3C´s linked to Kaizen as possible. The ratio 3C´s with Kaizen to the 3Cs which are not linked to kaizen are one measure of Lean maturity. To improve this ratio, and improve the number of 3C´s link to kaizen, a root cause analysis is necessary. This is where the 5x Why  comes in.

In the following example, which I personally use in trainings and is described in my book Lean Transformations , the use of the 5X WHY to help you find the real root cause of the problem is explained. As a Dutch guy, I like taking my bike to work. As a standard, I defined that my (random) tires should always be filled with air, up to a certain barometric pressure.

• On Monday morning, I plan to take the bike to work, when I realize I have a flat tire. I do a very quick 3C, without analysis, pump up the tire and cycle to work to make sure I do not miss my early morning meeting. This clearly is a quick fix solution, a back to the standard countermeasure.
• On Tuesday morning I want to cycle to work again, but realize the same tire is flat again. Apparently I have not analyzed the problem properly yesterday so today I ask myself why the tire is empty. I find there is a puncture in the tire which needs to be patched. After I patched the tire, I quickly cycle to work. Even though I did more than yesterday, this countermeasure is still a back to standard action.
• On Wednesday morning, my tire is flat for the third time this week. I´m starting to get annoyed but do take the time for a slightly better analysis than yesterday. Why is my tire flat? Because there is a puncture in the tire Why is there a puncture in the tire? Because a piece of glass got stuck into the outside tire. Solution: I remove the glass from the outer tire, patch the puncture, pump up the tire and cycle to work. I would ask the group now, whether I have raised the standard or that the countermeasure was a classical back to standard action. Just like Monday and Tuesday, even though I asked why a couple of times, removing the glass and patching the tire is still a back to standard countermeasure, as I was to find out on Thursday.
• On Thursday morning, I find myself with a flat tire again. This time however, I am motivated to do a real root cause analysis. Why is my tire flat? Because there is a puncture in it Why is there a puncture in my inner tire? Because a nail punctured through it. Why is there something puncturing my tire for the second time this week? The outer tire might not be protective enough to cycle through the rough streets of Hamburg. Solution: invest in new ´unbreakable´ tires over the weekend.

This last solution is the first solution this week that actually describes an improvement of the standard . Monday to Wednesday, I only executed some short term quick fixes to get my bike functioning again. Only on Thursday I found a possible root-cause for my problem, the reason I got ´so many´ flat tires. This led to a proper solution, in this case buying a better tire, to prevent something from puncturing it again.

The 3C´s described in this example, are visualizes in Illustration 2.

Illustration 2: Documented 3Cs, number 4 being the most desirable while it is linked to kaizen. (SOURE: Panneman, 2017 )

Having problems in keeping the standard is just one of the possible types of problems which can be addressed on the Team boards. There are three in total:

• The standard is not good enough (like the flat tire example)
• The standard is not achieved anymore, for instance a KPI that is ´red´
• A team member has identified one of the 8 wastes and would like to address it.

When all teams in an organization solve problems like these on a continuous basis using the root cause analysis, the performance of the organization will improve drastically. When the 3C´s are only used for firefighting, which means the standards are not being raised. There will be no measureable improvement of performance in the long term. A thorough root cause analysis is therefore one of the most important pin points in any (Lean) organization.

Continue to:

Lean Toolbox - Takt-, Cycle-, process- and Lead Time

REFERENCES:

Ballé, F., & Ballé, M. (2012).  De Lean Manager - een roman over een Lean Transformatie.  Driebergen (NL): Lean Management Instituut. ( summary  /  order this book )

Mann, D.,2005,  Creating a Lean Culture - Tools to sustain Lean Conversions , New York: Productivity Press. ( summary  / order this book )

Panneman, T, 2017,  Lean Transformations - when and  how to climb the four steps of Lean maturity,  Maarssen (NL): panview ( summary  /  Order this book )

Related Articles

5s in practice - sustain, 5s in practice - sweep and standardize, 5s in practice - sort and straighten.

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8D: Tools and Techniques

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• 8D Problem Solving

Are you grappling with recurring problems in your organization and searching for a structured way to resolve them once and for all? Look no further than the 8D Problem-Solving Methodology —a comprehensive eight-step approach initially developed in the automotive industry but widely applicable across various sectors.

This systematic method not only aids in diagnosing the root cause of a problem but also offers a roadmap for effective solutions. However, maximizing the potential of the 8D process involves more than just following its steps. It requires the strategic application of specific tools and techniques at each stage. In this educational blog post, we will guide you through the tools and techniques best suited for each of the 8 Disciplines, empowering you to turn challenges into opportunities for improvement. So, let’s delve into this toolkit and make your problem-solving journey as efficient and effective as possible.

Table of Contents

D1: form a team.

The first step in the 8D Problem-Solving Methodology is to form a cross-functional team. A well-assembled team is the backbone of any successful problem-solving initiative. While it may be tempting to rush through this step, investing time and effort here can pay dividends later. Let’s explore some of the key tools that can assist you in forming an effective team.

Suggested Tools:

1. raci matrix.

The RACI Matrix is an invaluable tool for defining roles and responsibilities within the team. The acronym stands for Responsible, Accountable, Consulted, and Informed. By using this matrix, you can clearly specify:

• Responsible : Who is doing the task?
• Accountable : Who is ensuring the task gets completed?
• Consulted : Who needs to provide input?
• Informed : Who needs to know the outcome?

Clear delineation of roles prevents overlap, ensures accountability, and minimizes confusion later in the process.

2. Skills Matrix

Selecting team members with the right set of skills is crucial. A Skills Matrix can help you in this aspect by providing a visual representation of each potential team member’s skills and competencies. You can rate skills on a scale (e.g., 1 to 5) and identify gaps that need to be filled. The matrix can include both technical and soft skills like communication, leadership, and domain expertise.

Key Takeaway:

An effective problem-solving team is not just a group of people; it’s a carefully chosen set of individuals with complementary skills and clearly defined roles. Utilizing tools like the RACI Matrix and Skills Matrix can immensely help in this phase, setting the stage for a successful problem-solving endeavor.

By taking the time to carefully form your team and define everyone’s roles and responsibilities, you lay a strong foundation for the rest of the 8D process. Remember, a well-prepared team is more likely to find sustainable solutions and less likely to encounter roadblocks down the line.

D2: Define the Problem

After assembling a competent team, the next critical step in the 8D Problem-Solving Methodology is defining the problem. A well-defined problem serves as a clear roadmap, guiding your team in the right direction from the start. Ambiguity at this stage can lead to misdirection and wasted resources. So what tools can help you clearly and concisely articulate the problem?

1. 5W2H Method

The 5W2H method is a powerful tool for problem definition. It involves asking a series of questions to gain a comprehensive understanding of the issue at hand. These questions include:

• Who is involved or affected?
• What exactly is the problem?
• When did it occur?
• Where did it occur?
• Why is it a problem?
• How did it happen?
• How much is it affecting?

By systematically answering these questions, you define the problem in a manner that is both comprehensive and easily understandable for everyone involved.

2. SMART Criteria

The SMART criteria focus on setting specific, measurable, achievable, relevant, and time-bound goals for the problem-solving effort. This approach helps ensure that the problem is clearly defined and that the team has a focused, achievable objective to aim for.

• Specific : Clearly define what needs to be achieved.
• Measurable : Set criteria for measuring progress and success.
• Achievable : Ensure the goals are realistic given the resources.
• Relevant : Align the goals with broader organizational objectives.
• Time-bound : Establish a timeline for solving the problem.

Defining the problem is not a mere formality; it is a necessity for effective problem-solving. A well-defined problem ensures that everyone is on the same page and focused on the right issues. Tools like the 5W2H method and SMART criteria offer invaluable frameworks for achieving this clarity. They help dissect the problem into manageable parts, setting the stage for focused root cause analysis.

D3: Contain the Problem

Once you have a team in place and a well-defined problem, the next step in the 8D Problem-Solving Methodology is containment. This stage is often overlooked but is crucial for limiting the damage and preventing the problem from exacerbating. Containment actions are essentially short-term solutions aimed at halting the spread of the issue while you work on finding a permanent fix. Let’s delve into some tools that can guide you in this phase.

1. Check Sheet

A Check Sheet is a simple yet effective tool for collecting and organizing data. It’s often a paper-and-pencil tool that allows for quick data collection in real-time. For example, if the problem is a high rate of defects in a manufacturing line, a Check Sheet could be used to tally the number of defects by type or time of occurrence. This provides valuable insights into the scope and pattern of the problem, aiding in containment.

2. SWIFT Checklist

The SWIFT (Short Window Immediate Fix Technique) Checklist is a tool designed for rapid assessment. It outlines immediate actions that should be taken to contain the issue. The checklist could include questions like:

• Are there safety issues that need immediate attention?
• Can the affected products be quarantined?
• Do stakeholders need to be informed?

By quickly going through the SWIFT Checklist, you can prioritize the most critical containment actions and implement them without delay.

Containment is not just about putting a temporary fix; it’s about preventing the problem from causing further harm or affecting other processes. Tools like the Check Sheet and SWIFT Checklist can be instrumental in quickly assessing the situation and implementing immediate containment actions.

Utilizing these tools allows you to create a rapid response mechanism, thereby minimizing the impact and scope of the problem. As you transition to finding a long-term solution, these containment measures ensure that the situation remains under control.

D4: Root Cause Analysis

Reaching the root cause analysis stage in the 8D Problem-Solving Methodology signifies a pivotal moment. Here, you transition from understanding and containing the problem to actually solving it. Identifying the root cause(s) is fundamental to ensuring that the issue doesn’t recur. While containment measures provide short-term relief, it’s the root cause analysis that offers a long-term solution. Let’s examine some essential tools that can assist in uncovering the underlying issues.

The “ 5 Whys ” is a powerful questioning technique that helps you drill down into the root cause of a problem by asking “Why?” repeatedly. Often, the apparent issue is just a symptom of a deeper problem. The 5 Whys technique encourages you to move beyond the symptoms and discover the underlying cause.

For instance, if the issue is frequent machine breakdowns, asking “Why?” might reveal:

• Why is the machine breaking down? Because of excessive wear and tear.
• Why is there excessive wear and tear? Because maintenance isn’t performed regularly.
• Why isn’t maintenance regular? Because there’s no schedule.
• Why is there no schedule? Because it was never made a priority.
• Why was it never a priority? Because of a lack of awareness about its importance.

2. Pareto Analysis

Pareto Analysis is based on the Pareto Principle, which states that 80% of problems are often due to 20% of causes. By identifying and focusing on these significant causes, you can resolve the majority of issues with minimum effort. Pareto Analysis typically involves collecting data and creating a Pareto Chart to visualize which factors are most impactful.

3. Fishbone Diagram (Ishikawa)

Though also used in problem definition, the Fishbone Diagram is invaluable for root cause analysis as well. It allows you to categorize potential causes and delve deeper into each, often in combination with other tools like the 5 Whys or Pareto Analysis.

Identifying the root cause is not merely a step in the process; it’s the cornerstone for effective corrective action. Tools like the 5 Whys, Pareto Analysis, and Fishbone Diagram provide a structured approach to dig deep into the problem and unearth its roots. Only by understanding the root cause can you implement solutions that are not just quick fixes but long-lasting remedies.

D5: Choose and Verify Corrective Actions

After identifying the root cause of the problem, the next logical step in the 8D Problem-Solving Methodology is to choose and verify corrective actions. It’s crucial to remember that not all solutions are created equal. Some may offer a quick fix but not a long-lasting one, while others could inadvertently introduce new issues. Therefore, this stage involves a delicate balance of selecting an effective solution and ensuring it doesn’t have unintended consequences. Let’s explore some of the tools that can guide you in making informed decisions.

1. FMEA (Failure Mode and Effects Analysis)

FMEA is a structured approach for evaluating the potential failure modes of a proposed solution and their impact. By predicting how things could go wrong, you can proactively address these issues before they occur. The FMEA process involves the identification of failure modes, assessment of their effects, and prioritization based on their severity, occurrence, and detectability. This prioritization helps you focus your resources where they’ll be most effective.

2. Pilot Testing

Before implementing a corrective action on a full scale, it’s prudent to test it on a smaller scale to verify its effectiveness. Pilot testing allows you to:

• Evaluate the impact of the solution without large-scale commitment.
• Identify any adjustments or optimizations needed.
• Collect data to validate the solution’s efficacy.

Pilot tests should be carefully designed to mimic the conditions under which the full-scale implementation will occur. This way, the results are indicative of what you can expect in the broader application.

Choosing a corrective action is a significant milestone, but verifying its effectiveness is equally crucial. Tools like FMEA and Pilot Testing enable you to rigorously evaluate your chosen solutions, mitigating risks and ensuring that the corrective actions will address the root cause without creating new problems.

By diligently applying these tools, you not only select the right corrective action but also build a robust verification mechanism. This two-pronged approach ensures that your solution is not just theoretically sound but practically effective as well.

D6: Implement Corrective Actions

Reaching the implementation phase of the 8D Problem-Solving Methodology is a big step. You’ve formed a team, defined the problem, contained it, identified its root cause, and chosen and verified corrective actions. Now, it’s time to put those actions into play. However, effective implementation is easier said than done. It requires meticulous planning, execution, and monitoring to ensure the corrective actions yield the desired results. Let’s look at some of the tools that can help you master this crucial stage.

1. Gantt Chart

A Gantt Chart is an excellent tool for project planning and tracking. It provides a visual timeline for the tasks involved in implementing the corrective actions. The chart specifies:

• Start and end dates
• Responsible parties
• Dependencies between tasks

This visual representation makes it easier to manage resources and timelines, ensuring that implementation stays on track.

2. PDCA (Plan-Do-Check-Act)

The PDCA cycle is a four-step approach for implementing changes in a controlled manner. Each step serves a specific purpose:

• Plan : Establish the objectives, processes, and metrics for the corrective action.
• Do : Execute the plan on a small scale initially.
• Check : Measure the outcomes against the planned objectives and analyze the results.
• Act : Make adjustments based on the analysis and either scale the implementation or revisit the plan.

By cycling through these steps, you can continually refine your implementation approach, ensuring it aligns with your objectives.

Implementation is the stage where your problem-solving efforts come to fruition, but it’s not a one-and-done deal. Effective implementation requires continuous monitoring and adjustment. Tools like the Gantt Chart and PDCA cycle provide you with the means to implement corrective actions in a structured, controlled, and measurable way.

Remember, a well-planned implementation not only solves the current problem but also equips your organization with the knowledge and experience to tackle future challenges more effectively.

D7: Prevent Recurrence

Successfully implementing corrective actions is an accomplishment, but the 8D Problem-Solving journey doesn’t end there. The next crucial step is to ensure that the problem doesn’t recur. This phase focuses on institutionalizing the improvements you’ve made, ensuring they are sustainable over the long term. It involves both documentation of new best practices and ongoing monitoring. Let’s explore the tools that can help solidify these new standards.

1. Standard Work

Standard Work refers to the documentation of the new best practices that led to the resolution of the problem. These could be new procedures, guidelines, or checklists that need to be followed. Standard Work serves multiple purposes:

• It provides a clear and easy-to-follow guide for team members.
• It ensures that the successful corrective actions are repeated, thereby making the improvements sustainable.
• It serves as a training resource for new employees or for refresher training for existing staff.

2. Control Charts

Control Charts are used to monitor process performance over time. These charts can help you:

• Identify any variations in the process.
• Distinguish between normal variations and those that need attention.
• Trigger corrective actions if the process goes out of the defined control limits.

Regularly updating and reviewing the Control Charts ensures that you catch any deviations before they turn into bigger problems.

Prevention is indeed better than cure. The most effective problem-solving initiatives are those that not only solve the immediate issue but also prevent its recurrence. Tools like Standard Work and Control Charts offer a structured way to document and monitor the improvements, making them a part of your organizational culture.

By diligently using these tools, you not only secure the gains made but also create a proactive environment where potential issues are identified and addressed before they escalate.

D8: Congratulate the Team

The final step in the 8D Problem-Solving Methodology is often the most overlooked but is crucial for long-term success: congratulating the team. After navigating through a complex problem-solving journey, taking a moment to acknowledge and celebrate the hard work is vital. It not only boosts morale but also encourages a culture of continuous improvement. Let’s delve into some tools and practices that can help you effectively close out your problem-solving initiative.

1. Recognition and Rewards

Acknowledging the hard work and dedication of the team is essential for maintaining a motivated and engaged workforce. Recognition can take various forms:

• Public acknowledgment in team meetings or company-wide announcements.
• Certificates or plaques to commemorate the achievement.
• Small rewards or bonuses, where appropriate.

This recognition serves as a reminder that efforts are appreciated, which in turn fosters a positive work environment.

2. Lessons Learned Document

Closing out a problem-solving initiative offers a prime opportunity to capture what worked and what didn’t. A Lessons Learned Document serves this purpose:

• It details the challenges faced, how they were overcome, and any roadblocks encountered.
• It captures best practices for future reference.
• It identifies areas for improvement, offering a starting point for future problem-solving endeavors.

Sharing this document organization-wide can serve as a valuable resource for other teams facing similar challenges.

A job well done indeed deserves recognition, but it also lays the groundwork for future improvements. Tools like Recognition and Rewards and the Lessons Learned Document not only celebrate success but also institutionalize the knowledge gained. This twofold approach not only marks the successful completion of one problem-solving initiative but sets the stage for ongoing improvements and future successes.

By taking the time to celebrate and reflect, you not only acknowledge the efforts made but also capture valuable insights that can guide your organization’s continuous improvement journey.

Successfully navigating the 8D Problem-Solving Methodology is a commendable achievement, but the journey doesn’t end with implementing a solution. Each step, from forming a team to congratulating them, is a building block in your organization’s culture of continuous improvement.

Employing specific tools like RACI Matrix, 5 Whys, FMEA, and Control Charts at different stages ensures that your problem-solving efforts are not just effective but also sustainable. These tools offer more than just a way to tackle issues; they provide a structured approach to learning from them. Remember, the goal isn’t just to solve a single problem but to refine a system that becomes increasingly resilient and efficient over time. So, take a moment to celebrate your achievements, and then gear up for your next challenge, armed with the knowledge and tools that will make your problem-solving journey even more impactful.

• Sharma, M., Sharma, S. and Sahni, S., 2020. Structured Problem Solving: combined approach using 8D and Six Sigma case study.   Engineering Management in Production and Services ,  12 (1), pp.57-69.
• Broday, E.E. and Júnior, P.P.A., 2013. Application of a quality management tool (8D) for solving industrial problems.   Independent Journal of Management & Production ,  4 (2), pp.377-390.
• Engineer, A.T.D., 2016. Managing project using 8D technique.   Management ,  7 (6), p.67œ76.

Daniel Croft

Daniel Croft is a seasoned continuous improvement manager with a Black Belt in Lean Six Sigma. With over 10 years of real-world application experience across diverse sectors, Daniel has a passion for optimizing processes and fostering a culture of efficiency. He's not just a practitioner but also an avid learner, constantly seeking to expand his knowledge. Outside of his professional life, Daniel has a keen Investing, statistics and knowledge-sharing, which led him to create the website learnleansigma.com, a platform dedicated to Lean Six Sigma and process improvement insights.

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