5 Effective Tools To Analyse Manufacturing Problems

5-Effective-Tools-To-Analyse-Manufacturing-Problems_1_11zon jaro

You cannot be successful in manufacturing management if you do not identify the real problem. If you are starting a systematic new way, it crucial to choose the right approach. A complicated and long method is unnecessary as it will waste time without results. The ideal choice would be choosing problem-solving tools.

It will address the actual problem and help you to solve the primary problems of management. Even though everyone has different reasons for using the problem-solving tool, the outcome will be positive for every professional.  So, let’s get started, and see various tools which will be helpful for you.

1. The Five Whys

The model is used by asking why it is required to find the cause of the problem 5 times. The five questions help teams continue to refine their processes and remove sources that are not useful. The framework is not usually digging deep, but uncovers the surface-level problems, works on them, and resolves them. 

However, the method is simple to use and solves all the complicated problems of the company. The lean method includes 5 or more ways to know the actual issues to resolve them.

2. Cause and Effect (Fix, Fish, and Tree)

The method used to know what is the cause of the problem. The method is practical and effective in addressing daily issues by manufacturing management. There are three ways based on Ishikawa or Fishbone diagrams. 

First is fix: used for what, who, and when. It helps find quick action to fix small issues which can be solved within a day.

The second is fish: used for a plan, do, check, and act. It helps to analyse the simple and repeat issues that can be solved in a week,

The third is the tree: used for logical solutions. It helps to analyse the reason behind complex root causes and remove multiple complex issues systematically. It can be solved in a month.

3. Pareto Chart

The Pareto chart is a bar chart combined with the line graph method. It helps groups to solve different problems and recurring costs. The Pareto charts are one of the seven primary tools of quality addressed by quality pioneer Joseph Juran. It is based on Pareto’s law, also called the 80/20 rule, which says that 20% of inputs drive 80% of results.

The charts allow you to check high-risk processes and check daily performance standards. It also helps you to identify process variations that cause defects and analyse them to find the root cause.

4. Process Mapping

It is difficult to measure the problem in the manufacturing industry because of the complexity and challenges to visualise. It helps to point out the actual mistake and eliminate unnecessary work or problems. The tool consists of a visual description of all organisation activities in the process, which should be done in the order.

You can opt for a course on manufacturing management to understand it in more detail.

5. Failure Mode and Effects Analysis (FMEA)

Every organisation should adopt FMEA to get positive outcomes. The method is used to explore potential failures or defects during process design or development. It helps to identify potential failures a company has to face, what will be the consequences and causes for it. The tool used at the beginning of the problem-solving process. 

Once you know the causes, the next step is to implement the solution and ensure that it will not repeat. Many organisations prefer online management courses to make employees understand them.


These tools help you to guide the identification of problems by analysing and visualising processes. The tools are useful and proven successful, however, it is good to complement them with online management courses with certificates. To get more details, visit Jaro Education and learn more about the manufacturing management course from IIM Tiruchirappalli.

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