I have no intention to replicate here the knowledge of standard quality tools. You may find this in the public domain.
Nevertheless I want to emphasize, that
- you cannot solve problems in meeting rooms
- you need to go to Gemba - the very spot where the problem
- you need to ask questions, why the problem occurred
- you must not accept answers from somebody, who is shooting
from the hip
- you have to insist on getting the full effect-cause-effect
- you have to insist on a verification of the problem.
If not - go back to square one or repeat complaints will remind you to do so.
Demings’s (or more precisely Shewart’s) PDCA approach is widely used in the industry.
A3, 8D, QRQC ... are just clones of PDCA, which is basically the scientific approach to problem solving. However most companies only pay lip service to the application of the PDCA methodology.
The picture on the right is supposed to emphasize this. It shows that the amount of effort going into PDCA should heavily lean on the “P” part. A proper PDCA is always done on the shop floor, in a cross functional workshop, with a board or flip chart and with lots of pictures, drawings and sketches.
In my humble opinion your number one quality tools are your feet, your eyes (or your seven senses) and your brain. Go to Gemba and use YOUR tools!
What used to be “quality circles” or “QRQC=quick response to quality concerns” is nowadays called “scrums”. This requires trained facilitators to manage and guide such workshops and I will be happy to assist your organization develop this capability.