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

WAYNE METALS SPECIFIC TOOLS Problem Solving & Root Cause Analysis

8-STEP PDCA PROCESS Introduced to Wayne Metals by Toyota Industrial Equipment

INTERNAL DEFECT COUNTERMEASURE LOG Follow 8-Step Memo #124 STANDARDIZATION/ YOKOTEN START INVESTIGATION FORM 04368 TEACH & TRAIN CONTAIN DEFECT 6, Revision: New Go 1,2 Department: 7, 8 (90 DAY NO DEFECT) and See 3 PIC: 4, 5 IMPLEMENT COUNTERMEASURES REPORT @ DAILY MEETING FIND ROOT CAUSE Issue # Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day) Status 1 Root Cause (Same Day) Date: By: Required: Y or N Found (Prevent from ever occurring again) List where & Date: Point of origin: Date: Current Situation: Where: (7) Teaching & Training (By 2nd Day) Who: Date Confirmed By (2) Containment (ASAP) Leaders: (4a) Countermeasure for Operators: In-House Date Implemented: Defect Description escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups: Date: PIC: How : Reported by: (To prevent flow out recurrence ) (8) Management confirms Date: Result: (6a) Standardize (By 2nd Day) activity good & kept 90 Days Date Date: Confirmed By How : 3/30/00 At Customer & in Transit Comments: Date: PIC: How : Result: Closed Date: Date Implemented:

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

STEPS 1 & 2-START IMMEDIATELY

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

Countermeasure STEP 4-COMPLETE WITHIN 24 HOURS

STEP 5-CONDUCT DAILY-ASAICHI OR YUICHI

WAYNE METALS YUICHI MEETING

STANDARDIZE, YOKOTEN, TEACH AND TRAIN, MANAGEMENT COMMITMENT

Issue # Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day) Status 1 Date: By: Root Cause (Same Day) Required: Y or N Found Point of origin: (Prevent from ever occurring again) List where & Date: Current Situation: Date: Where: (7) Teaching & Training (By 2nd Day) Who: Date Confirmed By (2) Containment (ASAP) Leaders: (4a) Countermeasure for Operators: In-House Date Implemented: Defect Description escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups: Date: PIC: How : (To prevent flow out recurrence ) Reported by: Date: (8) Management confirms Record current issues and post where can be seen. • Result: (6a) Standardize (By 2nd Day) activity good & kept Date: 90 Days Confirmed By Date How : CLEARLY identify who will take ownership to fix At Customer & in Transit 3/30/00 Date: PIC: Comments: How : problem. Result: Closed Date: Date Implemented: Issue # Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day) Status 2 Date: By: Root Cause (Same Day) Required: Y or N Found Point of origin: (Prevent from ever occurring again) List where & Date: Current Situation: Date: Where: • Used daily to visually track quick (7) Teaching & Training (By 2nd Day) Who: Date Confirmed By improvements of current issues (2) Containment (ASAP) Leaders: (4a) Countermeasure for Operators: In-House Date Implemented: Defect Description escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups: Date: PIC: How : (To prevent flow out recurrence ) Reported by: Date: (8) Management confirms Result: (6a) Standardize (By 2nd Day) activity good & kept Date: 90 Days Confirmed By Date How : At Customer & in Transit 3/30/00 • Eliminates “Out of sight, out of Date: PIC: Comments: How : mind” issues from recurring Result: Closed Date: Date Implemented: Issue # Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day) Status 3 Date: By: Root Cause (Same Day) Required: Y or N Found Point of origin: (Prevent from ever occurring again) List where & Date: Current Situation: Date: Where: (7) Teaching & Training (By 2nd Day) Who: Date Confirmed By (2) Containment (ASAP) Leaders: (4a) Countermeasure for Operators: In-House Date Implemented: • Proven extremely effective when Defect Description escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups: Date: PIC: How : (To prevent flow out recurrence ) Reported by: completed daily and required by Date: (8) Management confirms Result: (6a) Standardize (By 2nd Day) activity good & kept Date: 90 Days Confirmed By Date top management How : At Customer & in Transit 3/30/00 Date: PIC: Comments: How : Result: Closed Date: Date Implemented: Issue # Defect Picture (1) Genchi Genbutsu (ASAP) (3) Root Cause (Same Day) (4a) Countermeasure for (6b) Yokoten (By 2nd Day) Status 4 Date: By: Root Cause (Same Day) Required: Y or N Found Point of origin: (Prevent from ever occurring again) List where & Date: Current Situation: Date: Where: (7) Teaching & Training (By 2nd Day) Who: Date Confirmed By (2) Containment (ASAP) Leaders: (4a) Countermeasure for Operators: In-House Date Implemented: Defect Description escape prevention (Same Day) (5) Daily Meeting (Next Day) Back-ups: Date: PIC: How : (To prevent flow out recurrence ) Reported by: Date: (8) Management confirms :

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

3-LEGGED, 5- WHY

3-DIAMOND, 3-LEGGED 5-WHY

QUALITY OBSERVATIONS

DEFECT PREVENTION TOOLS

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

STANDARDIZATION & VISUALIZATION

WAYNE METALS UNIVERSITY & LEADERSHIP ACADEMY

WAYNE METALS MENTOR PROGRAM

COMMUNICATION

CHANGE POINT TRAINING & COMMUNICATION

SUSTAINABILITY

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

ADVANCED PRODUCT QUALITY PLANNING

LESSONS LEARNED CARD

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

EVERYONE IS AN INSPECTOR PROGRAM

THANK YOU!