LEARNING UNIT 2: PROBLEM SOLVING IN THE MANUFACTURING SECTOR

This learning unit introduces learners to structured problem-solving in manufacturing as a practical competence that combines analytical thinking, data use and effective teamwork.

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This learning unit introduces learners to structured problem-solving in manufacturing as a practical competence that combines analytical thinking, data use and effective teamwork. It helps participants understand how production problems should be defined, analysed and addressed through a disciplined process rather than through assumptions or quick fixes. The unit focuses on real shop-floor challenges such as defects, downtime, rework and process variation, and presents methods and tools that support evidence-based decision-making. At the same time, it highlights the importance of communication, coordination and follow-up in cross-functional environments, preparing learners to contribute to continuous improvement in a realistic industrial context.

LEARNING UNIT 2: Problem Solving in the Manufacturing Sector

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INTRODUCTION OF THE LEARNING UNIT
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LEARNING UNIT OUTLINE
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SECTION 1: Understanding and Defining Manufacturing Problems

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SECTION OVERVIEW
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LEARNING OUTCOMES
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LESSON 1: Structured problem-solving in manufacturing
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LESSON 2: Problem definition, scope and production data
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LESSON 3: Case study: defining and prioritising a production problem
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SUMMARY
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ASSESSMENT
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REFERENCES AND ADDITIONAL RESOURCES
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SECTION 2: Analysing Causes and Designing Countermeasures

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SECTION OVERVIEW
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LEARNING OUTCOMES
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LESSON 1: Root-cause analysis and cause validation
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LESSON 2: Designing effective countermeasures under manufacturing constraints
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LESSON 3: Practical exercise: root-cause analysis and countermeasure design
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SUMMARY
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ASSESSMENT
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REFERENCES AND ADDITIONAL RESOURCES
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SECTION 3: Implementing, Controlling and Sustaining Improvements

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SECTION OVERVIEW
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LEARNING OUTCOMES
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LESSON 1: Implementation, standardisation and KPI control
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LESSON 2: Team facilitation, communication and follow-up in problem solving
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LESSON 3: Practical exercise: mini-kaizen and final A3/8D presentation
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SUMMARY
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ASSESSMENT
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REFERENCES AND ADDITIONAL RESOURCES
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