Agent skill

A3CriticalThinking

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npx add-skill https://github.com/robdtaylor/personal-ai-infrastructure/tree/main/skills/A3CriticalThinking

SKILL.md

A3 Critical Thinking

When to Activate This Skill

  • "Create an A3 for [problem]"
  • "Help me think through [decision]"
  • "Root cause analysis for [issue]"
  • "What should take priority here?"
  • "Is this safe to proceed?"
  • "Evaluate tradeoffs for [options]"
  • "5 Whys analysis"
  • "Fishbone diagram for [defect]"

The Priority Hierarchy

Every decision must pass through this filter, in order:

┌─────────────────────────────────────────────────────┐
│  1. SAFETY FIRST                                    │
│     Will anyone be harmed? Stop everything else.    │
│     • Employee safety                               │
│     • Customer safety (product in use)              │
│     • Environmental safety                          │
│     • Community safety                              │
└─────────────────────────────────────────────────────┘
                        ↓ Only if SAFE
┌─────────────────────────────────────────────────────┐
│  2. CUSTOMER VALUE                                  │
│     Does this create good products for customers?   │
│     • Quality that meets/exceeds requirements       │
│     • Reliability and durability                    │
│     • On-time delivery                              │
│     • Fitness for purpose                           │
└─────────────────────────────────────────────────────┘
                        ↓ Only if QUALITY assured
┌─────────────────────────────────────────────────────┐
│  3. SHAREHOLDER VALUE                               │
│     Now optimize for business results               │
│     • Cost efficiency                               │
│     • Productivity                                  │
│     • Return on investment                          │
│     • Growth and sustainability                     │
└─────────────────────────────────────────────────────┘

Critical Rule: Never sacrifice a higher priority for a lower one. A cost saving that compromises safety is NEVER acceptable. A delivery acceleration that reduces quality is NEVER acceptable.

The Decision Test

Before any significant decision, apply this test:

Question 1: Is it SAFE?

  • Could this harm employees, customers, or the environment?
  • Are all safety controls in place?
  • Have we identified and mitigated risks?
  • If NO: STOP. Address safety first.

Question 2: Does it serve the CUSTOMER?

  • Will product quality be maintained or improved?
  • Does this meet customer specifications?
  • Will delivery commitments be met?
  • If NO: STOP. Find an alternative that protects quality.

Question 3: Is it EFFICIENT?

  • Only after safety and quality are assured, optimize for:
    • Cost reduction
    • Cycle time improvement
    • Resource utilization
    • Profitability

A3 Problem Solving Framework

The A3 is a single-page structured approach to problem solving:

┌─────────────────────────────────────────────────────────────────┐
│ TITLE: [Problem Name]                    DATE:                  │
│ OWNER: [Named Individual]                REV:                   │
├─────────────────────────────────────────────────────────────────┤
│ 1. BACKGROUND/CONTEXT         │ 2. CURRENT CONDITION            │
│                               │                                  │
│ Why is this problem important?│ What is actually happening?      │
│ What triggered this A3?       │ Data, facts, observations        │
│ Business impact               │ Process map of current state     │
│                               │ Quantify the gap                 │
├───────────────────────────────┼──────────────────────────────────┤
│ 3. TARGET CONDITION/GOAL      │ 4. ROOT CAUSE ANALYSIS           │
│                               │                                  │
│ What should be happening?     │ 5 Whys                           │
│ Specific, measurable target   │ Fishbone/Ishikawa                │
│ Timeline for achievement      │ Data analysis                    │
│                               │ Verified root cause(s)           │
├───────────────────────────────┴──────────────────────────────────┤
│ 5. COUNTERMEASURES                                               │
│                                                                  │
│ # │ Action               │ Owner    │ Due Date │ Status         │
│ 1 │                      │          │          │                │
│ 2 │                      │          │          │                │
│ 3 │                      │          │          │                │
├──────────────────────────────────────────────────────────────────┤
│ 6. IMPLEMENTATION PLAN        │ 7. FOLLOW-UP/RESULTS             │
│                               │                                  │
│ Gantt or timeline             │ Verification data                │
│ Resources required            │ Before/after comparison          │
│ Risks and mitigation          │ Lessons learned                  │
│                               │ Horizontal deployment?           │
└───────────────────────────────┴──────────────────────────────────┘

Root Cause Analysis Tools

5 Whys Method

Keep asking "Why?" until you reach the root cause (typically 5 levels):

Problem: Machine stopped producing
  Why? → Fuse blew
    Why? → Motor overheated
      Why? → Bearing failed
        Why? → Lubrication insufficient
          Why? → No preventive maintenance schedule

ROOT CAUSE: Missing PM program for bearings

Rules:

  • Each "Why" must be factual, not assumed
  • Verify each level before proceeding
  • May branch into multiple root causes
  • Stop when you reach something you can control

Fishbone (Ishikawa) Diagram

Categorize potential causes:

    Man          Machine        Material
      \            |            /
       \           |           /
        \          |          /
         ─────────[EFFECT]─────────
        /          |          \
       /           |           \
      /            |            \
   Method      Measurement    Environment

Manufacturing Categories:

  • Man/People: Training, skills, fatigue, following procedures
  • Machine: Equipment condition, calibration, capability
  • Material: Specifications, supplier quality, storage
  • Method: Procedures, work instructions, sequence
  • Measurement: Gages, accuracy, repeatability
  • Environment: Temperature, humidity, cleanliness, lighting

Countermeasure Hierarchy

When developing solutions, prefer higher levels:

Level Type Description Example
1 Eliminate Remove the possibility entirely Design out the feature
2 Substitute Replace with inherently safer/better Different material
3 Engineer Physical barriers or controls Interlock, guard
4 Administrate Procedures, training Work instruction
5 PPE/Inspect Last resort protection Check, verify

Rule: Never rely solely on administrative controls for safety-critical issues.

Quick Decision Framework

For rapid decisions under pressure:

┌─────────────────────────────────────────────┐
│         STOP AND ASK                        │
├─────────────────────────────────────────────┤
│ S - Safety: Is anyone at risk?              │
│ T - Target: What are we trying to achieve?  │
│ O - Options: What choices do we have?       │
│ P - Priority: Safety → Quality → Cost       │
└─────────────────────────────────────────────┘

If uncertain about safety: STOP PRODUCTION until verified safe.

Integration Points

With AutomotiveManufacturing Skill

  • A3 links to PFMEA updates when new failure modes identified
  • Countermeasures cascade to Work Instructions
  • Control Plans updated based on A3 findings

With HoshinKanri Skill

  • Red bowling chart items trigger A3
  • A3 countermeasures become improvement priorities
  • Completed A3s document breakthrough achievements

With Quality Systems (IATF 16949)

  • A3 satisfies 10.2 Nonconformity and Corrective Action
  • Links to 8D methodology for customer complaints
  • Supports Management Review inputs

Templates Available

Template Purpose Location
A3 Template Standard problem solving templates/a3-template.md
Quick A3 Simplified one-pager templates/quick-a3.md
5 Whys Root cause worksheet templates/5-whys.md
Fishbone Ishikawa diagram templates/fishbone.md
Decision Matrix Weighted option comparison templates/decision-matrix.md
Priority Check Safety-Quality-Cost verification templates/priority-check.md

Common Mistakes to Avoid

  1. Jumping to Solutions - Do root cause analysis first
  2. Blaming People - Look at systems and processes
  3. Stopping at Symptoms - Dig deeper with 5 Whys
  4. No Verification - Confirm countermeasures worked
  5. Ignoring the Hierarchy - Never shortcut Safety → Quality → Cost
  6. No Horizontal Deployment - Share learnings across similar processes
  7. Paper Exercise - A3 must drive real action

Key Principles

  1. Go See (Genchi Genbutsu) - Observe the actual condition yourself
  2. Facts Over Opinions - Base analysis on data and evidence
  3. Respect for People - Solutions should support workers, not blame them
  4. PDCA Cycle - Plan-Do-Check-Act is embedded in the A3
  5. One Problem, One Owner - Named individual accountability
  6. Visual Thinking - Use diagrams, charts, photos
  7. Priority Discipline - Safety → Customer → Shareholder, always

Extended Context

For detailed methodologies and advanced techniques: read ~/.claude/skills/A3CriticalThinking/CLAUDE.md

For templates: ls ~/.claude/skills/A3CriticalThinking/templates/

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