Module 1: Introduction to Structured Problem Solving Definitions: symptom vs. cause Cost of poor quality and recurring issues Overview of problem-solving models (PDCA, DMAIC, A3)

Module 2: Problem Identification and Definition Clearly defining the problem Problem scoping: when, where, how big, how often Tools: Problem Statement, SIPOC, Process Mapping

Module 3: Root Cause Analysis Fundamentals Introduction to Root Cause Analysis (RCA) Common pitfalls in identifying causes Importance of data and evidence gathering

Module 4: The 5 Whys Technique How to apply 5 Whys in a structured way When to stop asking “why” Group exercise: 5 Whys on real scenarios

Module 5: Fishbone (Ishikawa) Diagram Categorizing root causes: Man, Machine, Method, Material, etc. Building and analyzing a cause-and-effect diagram Interactive workshop: team-based Fishbone exercise

Module 6: Fault Tree Analysis (FTA) Logic-based cause identification Mapping failure paths using AND/OR gates Practical example: safety or system breakdown

Module 7: Failure Modes and Effects Analysis (FMEA) Identifying and prioritizing failure modes Risk Priority Number (RPN) and mitigation planning FMEA in process vs. product analysis

Module 8: Verification and Validation of Root Causes Confirming the root cause through data and tests Avoiding false positives and misdiagnoses Case study reviews and critique

Module 9: Developing and Implementing Corrective Actions Brainstorming and evaluating solutions SMART corrective actions Building action plans and assigning accountability

Module 10: Preventing Recurrence and Sustaining Results Change management and documentation Standardization and knowledge sharing Creating a proactive problem-solving culture  Materials Provided Course workbook with RCA templates RCA and FMEA worksheet samples Case studies and assessment tools Certificate of Completion Post-course support for real implementation