Problem Solving as a Core Capability
It's time to stop treating it as a side task
Why Manufacturing Quality Efforts Still Miss the Mark — and What to Do About It
Manufacturers are deeply committed to producing defect-free, high-quality products. That commitment shows up in many ways — investment in advanced testing equipment, compliance with ISO standards, layers of quality metrics, and dedicated quality assurance teams. Yet despite all this effort, many organizations still fall short of world-class performance.
Why?
The answer lies in how we approach the cost of quality.
Consider the four categories of the cost of quality.
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When you break down the costs — prevention, appraisal, internal failure, and external failure — it becomes clear: the lion’s share of quality costs are tied to failure. But most quality teams are focused almost entirely on prevention and appraisal. Very few are actively working on reducing failure costs — the part that hits the bottom line the hardest.
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It’s Time to Rethink Problem Solving
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In many plants, problem-solving tasks are assigned to people with no formal training in structured methodologies. But real, sustainable problem solving is a specialized skill and it requires training, tools, and lots of practice.
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When manufacturers invest in structured, high-skill problem solving, the payoff is massive:
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Quality improves
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Profitability increases
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Teams get better at preventing future issues
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Process knowledge deepens
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And unlike many capital investments, this one pays off fast — and keeps paying.
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What You Can Do Next
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If you’re serious about improving performance, here’s where to start:
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Track your failure-related costs
Get a clear view of what poor quality is really costing you. -
Prioritize based on financial impact
Focus on the issues that cost the most. -
Create a dedicated problem-solving team
Free them from all other tasks so they can concentrate on root cause analysis. This becomes a full-time role. Amend your organization chart to reflect this. -
Train them well
Equip your team with training in advanced tools and methods. (Programs like Belfield Academy’s Industrial Problem Solving are a great starting point.) -
Engage leadership
Meet regularly to review progress and extract insights that benefit the entire operation.
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The Bottom Line
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Imagine your operation without its top ten quality issues. Imagine the boost in throughput, yield,
and morale.
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The first step? Start treating problem solving not as a side task, but as a core capability.
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I can certainly help with the employee training part. My course on Industrial Problem Solving - Advanced Techniques is the best you'll find on this topic. It takes about two semesters for a student to complete and covers the following topics;
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linear regression
logistic regression
hypothesis testing
statistical process control
clue generators
statistical engineering
design of experiments
Problem solvers need statistical software for many things, not the least of which is simply generating charts of their data. In my course, students will learn to use R and RStudio. Both are open-source and free to use.
On completion of the course, students will receive a certificate of completion. If a student passes their mid-term and final exams, they will earn a certification as a Problem Solving Journeyman. If a student also submits a qualified project, they will be certified as a Problem Solving Master.
This is a great investment in your people and the returns are among the highest you'll find anywhere. 10x to 100x on the first project and the returns keep coming with every project.
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