The A3 report as a problem-solving tool in a manufacturing enterprise – case study

Abstract

Purpose: This article aims to analyze a problem occurring in the pipe production process and then solve it using the A3 report. The analysis was conducted using a production plant in Poland, where non-compliance was identified as gel lumps on the inner surface of pipes, affecting the quality, durability, and safety of use of finished products. Solving the problem using the A3 report methodology enabled understanding of the problem, analysis of its root causes, and development of an action plan, while engaging the team in the improvement process. Design/methodology/approach: The A3 report was used for the analysis as a tool to support problem-solving in the production environment. According to the A3 report methodology, the problem-solving process included seven stages: defining the problem, analyzing current conditions, defining the action objective, identifying the root cause, defining countermeasures, developing an implementation plan, and defining further actions (monitoring results and drawing conclusions). Findings: Using the A3 report allowed the identification of the root cause of the problem being analyzed, and taking preventative measures and standardizing the process effectively resolved the problem and prevented its recurrence. The results obtained were also passed on to other company plants as source material. Research limitations/implications: The analysis focused on a single issue in the company's pipe production process, which limits the ability to compare the results regarding the effectiveness of the A3 report as a problem-solving tool at this plant. Furthermore, the effectiveness of the implemented actions was observed over a limited time period. The results obtained may also depend to some extent on the competence and commitment of the team conducting the analysis, which constitutes a further direction for research in this area. Originality/value: This article is a case study and presents the practical application of the A3 report in the process of solving a specific problem at a manufacturing company in Poland. The work serves as source material for the company where the analysis was conducted and can also be a source of knowledge for other companies undertaking similar activities. Furthermore, the conducted research can serve as a reference point for further research and comparative analyses in industrial practice. Keywords: the A3 report, Problem-Solving, PDCA, continuous improvement, Lean Manufacturing. Category of the paper: research paper, case study.