Critical Thinking and Complex Problem Solving at Work

Analyze why accidents happen by examining human factors, process variability, unforeseen scenarios, and randomness to identify risks and prepare for future incidents.

Explore the Swiss cheese model and how holes in barriers align to cause accidents, despite defenses like control defenses, mitigation defenses, and crisis management actions.

Identify randomness in workplace outcomes. Remember not everything is under control and strengthen processes by brainstorming failure points, adding defenses such as quality control and automation to reduce randomness.

When issues occur, move quickly to information gathering, use the Swiss cheese model to manage risk, contain impact, and identify root causes, so the future is under our control.

This lecture presents a practical detection case in a quality system, comparing two approaches to rising defects and applying root-cause analysis, containment, and emotional intelligence under pressure.

Classify problems as new or chronic, then gather information, collect data to identify root cause at origin. Emphasize traceability, timing, frequency, and proximity to the occurrence point for accurate data.

Communicate with issue reporters to identify essential information and initiate investigation. Visit the Gemba to observe the process and talk with frontline staff, using data and KPIs to guide solving.

Explore information collection in a manufacturing case by compiling possible causes, verifying process parameters like temperature and cooling time, and communicating findings to specialists.

Analyze collected data to form hypotheses about the root cause, identifying patterns and connections while filtering distortions and comparing facts across sets.

Identify bias in decision making and data analysis, conscious or unconscious, by checking evidence and pausing to reflect on biased thoughts with examples; consider Thinking Fast and Slow.

Explore a practical analysis exercise where the team uses a fishbone diagram to identify root causes—from equipment and process to materials, environment, and measurement—of a defect, including a supplier change.

Eliminate or investigate causes by analyzing data, consulting specialists, and testing each option against facts. Use a fishbone diagram to methodically narrow root causes and move to the next step.

Shift from elimination to validation mode and test raised points using varied methods based on available resources, such as bibliographic search, lab input, temporal data, or small-scale simulations.

Validate root causes with simple, reliable solutions first, using clear validation methods and an action plan, avoiding overengineering and embracing simplicity when possible.

Apply a structured critical thinking framework to eliminate and validate hypotheses for a casting defect, using a fishbone diagram and data-driven tests to identify the root cause.

Identify root causes and apply a simple action plan with a clear description (present-tense verb), one responsible, and a firm deadline, with 5W2H as a common modeling option.

Define action plans together with all involved, align on responsibilities and deadlines after root cause investigation, and commit publicly via a shared whiteboard with signatures to ensure accountability.

Explore three types of actions for complex problems: containment, correction, and corrective action, or preventive action, focused on minimizing damage, solving the issue, and eliminating root causes to prevent recurrence.

Involve everyone affected from the start while designing actions. Analyze effectiveness through indicators, tests, or simulations to verify root cause accuracy and action impact within the plan.

Apply the three action types—containment, correction, and corrective action—to solve defects, install thermocouple measures, and validate results by defect rate, while documenting and sharing the plan.