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A3 Problem-Solving for Engineers

This document describes the Toyota-style A3 problem-solving report process. It includes: 1) Studying the current problem by observing the work context, documenting the current condition, validating observations, and quantifying the problem extent. 2) Developing countermeasures by generating improvement ideas, designing specific changes, and envisioning a target condition. 3) Implementing the plan by carrying out assigned actions by deadlines, measuring the effects on schedule, and researching differences from predictions.

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Saúl Pumapillo Gómez
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111 views4 pages

A3 Problem-Solving for Engineers

This document describes the Toyota-style A3 problem-solving report process. It includes: 1) Studying the current problem by observing the work context, documenting the current condition, validating observations, and quantifying the problem extent. 2) Developing countermeasures by generating improvement ideas, designing specific changes, and envisioning a target condition. 3) Implementing the plan by carrying out assigned actions by deadlines, measuring the effects on schedule, and researching differences from predictions.

Uploaded by

Saúl Pumapillo Gómez
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Toyota-Style Problem-solving A3 Reports

Adapted by
Durward K. Sobek, II
Assistant Professor
Dept. of Mechanical and Industrial Engineering
Montana State University
Bozeman, MT 59717-3800
Tel. 406-994-7140
Fax 406-994-6292
dsobek@ie.montana.edu

This material is based upon work supported by the National Science Foundation under Grant No. SES-0115352.
The A3 Report
To:___________________
THEME: "What are we trying to do?" By: ___________________
Date:__________________

Background Target Condition

 Background of the problem


 Context required for full understanding  Diagram of proposed new process
 Importance of the problem  Countermeasures noted as fluffy clouds
 Measurable targets (quantity, time)

Current Condition

 Diagram of current situation (or process).


 Highlight problem(s) with storm bursts.
 What about the system is not IDEAL. Implementation Plan
 Extent of the problem(s), i.e., measures.
What? Who? When? Where?

Actions to be Responsible Times,


taken person Dates

Cost:
Cause Analysis

 List problem(s) Follow-Up


 Most likely direct (or root) cause: Plan Actual Results
Why?  How will you check the  In red ink/pencil.
Why? effects?  Date check done.
Why?  When will you check them?  Results, compare to
Why? predicted.
Why?
Target State for A3 Problem-Solving
Studies
Problem.

Encounters


Problem. Devises
Countermeasures.
(A3)

Measures
Effects.

Implement

Builds consensus with


Implements affected parties.
Plan.
Gets
Approval.
Target State for A3 Problem-Solving
(see attached figure)

Encounters Problem Gets approval


 Something about the way work happens now is not  The appropriate authority verifies that problem has been
IDEAL. sufficiently studied.
 The authority verifies that all affected parties are “on
Studies Problem board” with the proposal.
 Observe the work in its actual context.  Appropriate authority approves the change and
 Document the current condition. implementation.
 Validate observations.
 Quantify the extent of the problem. Implements plan
 Perform cause analysis: is work properly specified? Are  Each person listed in implementation carries out his/her
connections clear, direct, yes/no? Are pathways simple, assignment by the deadline.
direct, and uninterrupted?
 Write the left-hand half of the A3. Measures effects
 On the date specified in the follow-up plan, measure the
Devises Countermeasures results of implementation and document.
 Generate ideas to move the organization closer to  If results differ from predicted, research why.
IDEAL.  On to the next problem!
 Design specific countermeasures that i) specify the work,
ii) create better connections, and/or iii) simplify pathway.
 Involve the people affected by the change; get their ideas,
their reservations.
 Envision and document a target condition.
 Devise an implementation plan: what, who, when, and
desired outcome.
 Predict the results of implementation quantitatively.
 Decide on a follow-up plan.
 Write the right-hand half of the A3.

Builds consensus with affected parties


 Build consensus with ALL people affected by the
implementation or target condition.
 May involve studying problem further or reworking the
target condition.

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