Solving Problems at All Levels

🎯 Insight: Most Problems Are Contained, Not Solved

Many organizations only contain problems instead of solving them to their root cause. While eliminating a specific issue is valuable, true operational excellence requires a deeper approach—addressing problems at three levels to build a highly reliable organization that can sustain long-term success.

💡 The Idea: Address Three Levels of Problems

To create lasting improvements, organizations should analyze problems at three distinct levels:

1️⃣ Specific Problem – Why did the problem occur?

• Identify the root cause(s) and apply an irreversible countermeasure to prevent recurrence.

• Avoid focusing too narrowly—broader opportunities may exist beyond the immediate fix.

• Leverage standardized work and error-proofing (poka-yoke) techniques to ensure the problem does not resurface.

2️⃣ Detection Problem – Why wasn’t the problem detected earlier?

• Strengthen detection systems to identify issues before they escalate, minimizing impact and costs.

• Use real-time monitoring, visual management, and automated alerts to catch problems sooner.

• Accept that problems will happen but work to catch and contain them faster through predictive analytics and digital tools.

3️⃣ Systemic Problem – Why did the operating system allow it to happen?

• Examine organizational systems, work design, leadership behaviors, and culture that enabled the issue.

• Recognize interdependencies—a process is part of a system, and a system is part of a bigger system.

• Use Lean principles, management system design, and structured problem-solving frameworks to address systemic weaknesses.

• Foster a culture of continuous improvement and knowledge-sharing to prevent similar issues across different departments.

☝️ Tips: Using the ‘5 Whys’ Method at Every Level

• Apply 5 Whys at each problem level to uncover deeper root causes and prevent short-term fixes.

• Encourage cross-functional collaboration to capture systemic insights and break down organizational silos.

• Use problem-solving efforts to drive continuous learning and system improvements—embedding a mindset of relentless improvement.

• Invest in leader standard work to ensure leaders are coaching their teams on proactive problem-solving daily.

💭 Your Turn: How Does Your Organization Solve Problems?

Does your team address all three levels of problem-solving?

What strategies have you found most effective in creating lasting improvements?

Let’s discuss! 🚀