Practice 30 Continuous Improvement Engineer interview questions covering Lean, Six Sigma, and process optimization.
Question 3 of 30
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There are many ways to use structured problem solving to solve problems and make improvements. Oftentimes different organizations have different methodologies they prefer, they will likely even have different methodologies they apply depending on the type problem at hand (i.e. cost savings follow an A3 approach while quality issues are solved using an 8D). Since the company will likely offer detailed training on their preferred methodology, the intent of this question isn't to determine if the candidate is an expert at a specific problem solving approach. Rather, the question is used to determine whether the candidate has experience using a structured methodology to solve problems. It is common for western-thinkers to focus on solutions before they fully understand a problem, for a CI engineer it is imperative that a problem is fully understood before a solution is generated. This is an ideal time for the candidate to demonstrate their understanding of cause and countermeasure thinking.
"I have experience using a variety of methodologies to solve problems, I have used fish-bones, 8Ds, and A3s to solve problems in the past. Depending on the scope and level of complexity of a problem, I have found that different strategies should be used. At my last job, we had a particular defect that occurred in our production process. The defect had been occurring for some time and many team-members had an opinion on what was causing it, but no one had been successful in eliminating the defect. We decided to complete an A3 on the problem, after meeting with the team and fully understanding the problem we identified four contributing factors that lead to the occurrence of this defect. We implemented countermeasures for all four factors and the rate of defect occurrence was decreased by 80%."

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