WAYNE METALS SPECIFIC TOOLS Problem Solving & Root Cause - - PowerPoint PPT Presentation

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WAYNE METALS SPECIFIC TOOLS

Problem Solving & Root Cause Analysis

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8-STEP PDCA PROCESS

Introduced to Wayne Metals by Toyota Industrial Equipment

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FORM 04368

STANDARDIZATION/ YOKOTEN START INVESTIGATION

Revision: New

TEACH & TRAIN CONTAIN DEFECT

Department:

(90 DAY NO DEFECT)

PIC:

IMPLEMENT COUNTERMEASURES REPORT @ DAILY MEETING FIND ROOT CAUSE

Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day)

Date: By:

Root Cause (Same Day)

Required: Y or N

Point of origin: (Prevent from ever occurring again) List where & Date:

(7) Teaching & Training (By 2nd Day) (2) Containment (ASAP) Leaders:

In-House

(4a) Countermeasure for

Date Implemented:

Operators: Defect Description

Date: PIC:

escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups:

(To prevent flow out recurrence )

Reported by: Date:

(8) Management confirms (6a) Standardize (By 2nd Day) activity good & kept

Date:

90 Days

At Customer & in Transit Date: PIC:

Date Implemented:

How : Result: How : Result: How :

Comments:

Current Situation:

INTERNAL DEFECT COUNTERMEASURE LOG

Issue # Status 1 Found 3/30/00

Follow 8-Step Memo #124

Confirmed By

Date

Confirmed By

Date Date: Where: Who: Closed Date:

1,2 6, 7, 8 3 4, 5

Go and See

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FOLLOW THE 8 STEP METHOD EVERY TIME

• 1. Genchi-Genbutsu “Go and See”
• 2. Contain
• 3. Root Cause
• 4. Countermeasure
• 5. Asaichi
• 6. Yokoten/Standardize
• 7. Teach/Train
• 8. Daily Management Control

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STEPS 1 & 2-START IMMEDIATELY

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STEP 3-COMPLETE AT “GO AND SEE”- GENCHI GENBUTSU

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STEP 4-COMPLETE WITHIN 24 HOURS

Countermeasure

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STEP 5-CONDUCT DAILY-ASAICHI OR YUICHI

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WAYNE METALS YUICHI MEETING

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STANDARDIZE, YOKOTEN, TEACH AND TRAIN, MANAGEMENT COMMITMENT

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Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day)

Date: By:

Root Cause (Same Day) Required: Y or N

Point of origin: (Prevent from ever occurring again) List where & Date:

(7) Teaching & Training (By 2nd Day) (2) Containment (ASAP) Leaders:

In-House

(4a) Countermeasure for

Date Implemented:

Operators: Defect Description

Date: PIC:

escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups:

(To prevent flow out recurrence ) Reported by: Date:

(8) Management confirms (6a) Standardize (By 2nd Day) activity good & kept

Date:

90 Days

At Customer & in Transit Date: PIC: Date Implemented:

Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day)

Date: By:

Root Cause (Same Day) Required: Y or N

Point of origin: (Prevent from ever occurring again) List where & Date:

Date: Where: (7) Teaching & Training (By 2nd Day) Who: (2) Containment (ASAP) Leaders:

In-House

(4a) Countermeasure for

Date Implemented:

Operators: Defect Description

Date: PIC:

escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups:

(To prevent flow out recurrence ) Reported by: Date:

(8) Management confirms (6a) Standardize (By 2nd Day) activity good & kept

Date:

90 Days

At Customer & in Transit Date: PIC: Date Implemented:

Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day)

Date: By:

Root Cause (Same Day) Required: Y or N

Point of origin: (Prevent from ever occurring again) List where & Date:

Date: Where: (7) Teaching & Training (By 2nd Day) Who: (2) Containment (ASAP) Leaders:

In-House

(4a) Countermeasure for

Date Implemented:

Operators: Defect Description

Date: PIC:

escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups:

(To prevent flow out recurrence ) Reported by: Date:

(8) Management confirms (6a) Standardize (By 2nd Day) activity good & kept

Date:

90 Days

At Customer & in Transit Date: PIC: Date Implemented:

Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day)

Date: By:

Root Cause (Same Day) Required: Y or N

Point of origin: (Prevent from ever occurring again) List where & Date:

Date: Where: (7) Teaching & Training (By 2nd Day) Who: (2) Containment (ASAP) Leaders:

In-House

(4a) Countermeasure for

Date Implemented:

Operators: Defect Description

Date: PIC:

escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups:

(To prevent flow out recurrence ) Reported by: Date:

(8) Management confirms

How :

:

Result: How :

Comments:

How : Result: Confirmed By

Date 3 Found

How : Current Situation: Current Situation: How : Result: How : Result: How :

Comments:

Current Situation:

Issue # Status 1 Found 3/30/00

Confirmed By

Date

Confirmed By

Date Date: Where: Who: Issue # Status 2 Found Closed Date:

How :

Issue #

Result: How :

Comments:

How : Result:

Date Closed Date: Status Issue # Status 4

Current Situation:

Found

Confirmed By

Closed Date:

Confirmed By

Date

Confirmed By

Date 3/30/00 3/30/00

Confirmed By

Date

• Record current issues and post where can be seen.

CLEARLY identify who will take ownership to fix problem.

• Used daily to visually track quick

improvements of current issues

• Eliminates “Out of sight, out of

mind” issues from recurring

• Proven extremely effective when

completed daily and required by top management

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PROBLEM SOLVING TOOLS TO USE DURING “GO AND SEE” PHASE

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3-LEGGED, 5- WHY

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3-DIAMOND, 3-LEGGED 5-WHY

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QUALITY OBSERVATIONS

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DEFECT PREVENTION TOOLS

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1. Standardization 2. Visualization 3. Training 4. Communication 5. Sustainability

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STANDARDIZATION & VISUALIZATION

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WAYNE METALS UNIVERSITY & LEADERSHIP ACADEMY

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WAYNE METALS MENTOR PROGRAM

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COMMUNICATION

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CHANGE POINT TRAINING & COMMUNICATION

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SUSTAINABILITY

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STRUCTURING MANUFACTURING FLOOR TO ENGAGE ALL EMPLOYEES IN QUALITY IMPROVEMENT ACTIVITIES.

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ADVANCED PRODUCT QUALITY PLANNING

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LESSONS LEARNED CARD

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WEAK POINT MANAGEMENT

Improvement tool used to Visualize and Prioritize types of issues to provide guidance toward actions to improve.

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EVERYONE IS AN INSPECTOR PROGRAM

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THANK YOU!