A3 The basic problem

solving tool

What is the A3?

A3is a structured problem solving and continuous

improvement approach, first employed at Toyota and
typicallyusedbyleanmanufacturingpractitioners.
A3is a simple and strict approach systematically
leading towards problem solving over structured
approach.

What is the A3?

A3leadstowarsproblemsolvingoverthestructure,placed
ontheISOISOA3singlesheetpaper(28x43cm).Thisis
thereasonbytheprocessgotthisname.
A3isalsocalledSPSSystematicProblemSolving
A3isbasedontheprinciplesofDemingPDCAPlanDo-
CheckAct

5
Problem Definition

Action Plan

2
Actual Situation

6
Follow up

3
Causes Analyze
4
Objective Situation

7
Results

STEP 1
Describing and
defining the problem

DEFINE THE PROBLEM

Clear
Use
Be

and concise definition of the problem.

quantitative data.

objective.

CURRENT CONDITIONS
Process

and environment details.

DESCRIBE THE PROBLEM 5W+1H

CATEGORY
Asunto
Cuantificacin

5W + 1H

GOALS

WHAT?

Quseestareportando?
Quimplica?

Identificarelfocode
anlisis

WHEN?

Cundoocurriporprimeravez?

Ubicacinenel
tiempo

WHERE?

Dndesepresentaelproblemay
dndenosepresentaperose
pudierapresentar?

Lugarfsicodonde
ocurrenloshechos

WHY?

Porquocurreahelproblema?
Porquhastaahoralonotamos?
Porqunadiedioavisoprevio?

Identificarlaolas
causasquegeneran
elproblema

WHO?

Quinlovioporprimeravez?
Quinloreporta?
Aquienesafecta?

Identificaralos
usuariosy/oafectados

Qutantoimpacta?
Qutangravees?

Estableceseveridad
delproblema

Ubicacin

Causas

Usuario
HOWMUCH?
Secuencia

PREGUNTAS TPICAS

STEP 2
Root Cause Analysis

ROOT CAUSE ANALYSIS

Whydoestheproblemor
needexist?
Whyarecustomersbeing
shippedbadproducts?
Why doesnt the system
wasreliabletodetectit?

5 Whys?
Why?
Why?
Why?
Why?
Why?

5 WHYs
Whyitsdamagingthestatue?
Because is washed it too often!

Why its
damaging the
statue of the
Thinker by A.
Rodin?

Whytheywashedittoooften?
Because there are many birds and leave
their droppings!

Whytherearemanybirds?
For the birds like to eat the spiders that
are there.
Whytherearespiders?
For the spiders like to eat the fireflies that
are there.

ROOT
CAUSE

Whytherearefireflies?
Because park visitors like to observe the statue
at night.

CAUSE - EFFECT
Method

Machinery

Pressing
incorrect
data

IrregularPressionof
HidraulicSystem.

Measurements

Tool

Specifications
Poor design tool

Maintenance

Insufficient
stock

Incorrect terms
of tools.

Wrongparallelism

Clumps
Incorrect
definition of pf.

Lackof
5Ss

Excess
humidity

Temperature
LackofTraining
overtemperature

Incorrectdust

Materials
Dust

Uneven
density

Workforce

Environment

Press 200 Ton

Lackofmaintenance

Fractures

BRAINSTORM

Incorrectinspection
method.

Time repair tool

undefined .

IncorrectPeripheralTerms

STEP 3
Action Plan

ACTION PLAN
We

have an essencial description of

the problem, we have identified the
causes and objectives. Now we define
the actions indicating who does what,
how, when

STEP 4
Implementation

IMPLEMENTATION
5 Por qus
Por qu seestdaandolaestatua?
Porquelalavanmuyseguido!
Plan de Accin:Cambiomtododelimpieza
Por qu lavanlaestatuatanseguido?
Porquehaymuchasavesydejansuexcremento!
Plan de Accin: Colocaunamalla

Por qu seest
daandolaestatua
delpensadorde
A.Rodin?
1. Temporalmente correctiva
2. Parcialmente correctiva

Por quhaymuchasaves?
Alasaveslesgustacomerlasaraasquehayah!
Plan de Accin: Fumigueelareacontraaves

3. Totalmente correctiva

Por quhayaraas?
Alasaraaslesgustacomerlosinsectos
quehayahi!
Plan de Accin: Fumigueelareacontraaraas
Por quhayinsectosah?
Porquealosvisitanteslesgustaobservarla
estaturadenoche
Plan de Accin: Cierreelparquedurantelanoche

4. Parcialmente
preventiva
5. Totalmente
preventiva

STEP 5
Verifies the
effectiveness