Who this course is for
Team Leaders, Supervisors, Maintenance Leaders, Quality Leaders, Production Managers and Plant Managers — anyone responsible for solving operational problems and preventing recurrence.
Why this course matters
Most organisations solve the same problems repeatedly — because the approach jumps from symptom to solution without understanding the real cause. This course develops the thinking discipline that prevents recurrence.
What you will learn
- Problem definition — standard vs actual condition
- Gap and impact analysis
- Pareto analysis
- Fishbone (Ishikawa) diagram
- 5 Whys — occurrence, detection and system causes
- Verification at the Gemba
- Correction, Corrective Action, Preventive Action and Systemic Prevention
- A3 thinking and mini-A3
- PDCA cycle
- Action follow-up and effectiveness verification
- Lessons learned and knowledge transfer
Course structure
- Module 1: Understanding the problem — definition and gap
- Module 2: Root cause analysis — Pareto, Fishbone, 5 Whys
- Module 3: Verification at the Gemba
- Module 4: Action planning — correction, CAPA, prevention
- Module 5: A3 thinking and PDCA
- Module 6: Follow-up, effectiveness and lessons learned
What you will be able to do after this course
Define problems precisely, analyse root causes systematically, verify causes at the Gemba and create action plans that eliminate recurrence — not just correct symptoms.
Duration and format
18–26 hours over 3–5 weeks
Blended course or on-site problem-solving sprint.