Investigative Problem Solving

Brainstorming finds suspects.

Evidence finds the cause.

In-house root cause training for manufacturers. Your quality engineers learn to find the true cause with data, not guesswork, so problems stay fixed.

Why defects keep coming back

Your team ran the 8D. The defect was contained, the report was signed off, and a few weeks later it was back. That isn't a people problem. It's a method problem.

Most problem-solving starts with a brainstorm or a fishbone diagram. The team lists dozens of possible causes, agrees on the most likely one, and fixes it. When the symptom fades, the case is closed. But a guess that seems to work is not a root cause, and the real cause is still in the process.

Investigative Problem Solving: let the evidence lead

Study the defect. Compare good and bad parts to pin down exactly what differs.

Trace it upstream. Use process and supplier data to find where the difference first appears.

Sample smartly. Small, well-planned samples rule out whole families of causes at once.

Prove it. Turn the cause on and off and show the defect follows, backed by statistics.

Training at your plant, on your problems

Free 1-hour lunch-and-learn: a working session for your quality and process engineers, using one of your own recurring defects as the example. No obligation.

5-day in-house course: hands-on training in Investigative Problem Solving, sampling, applied statistics and R, delivered at your site. Your team works on real defects from your line, so you get results while they learn.

B.C. employers may recover up to 80% of training costs through the B.C. Employer Training Grant. Ask me how it works.

Your instructor

Chris Butterworth, Six Sigma Master Black Belt

I have 35+ years in manufacturing, leading quality and continuous improvement in lithium battery, electronics, plastics and high-tech plants, including Northvolt, EaglePicher Energy Products and Ballard. I taught Lean Six Sigma at BCIT for 13 years and hold five ASQ certifications: CMBB, CSSBB, CQE, CMQ/OE and CRE.

I teach what I've done on the factory floor: finding the real cause of stubborn defects, and making sure they don't come back.

Have a defect that won't stay fixed?

Tell me about it. In 20 minutes we'll talk through what's happening and whether training would help your team. No sales pitch.