AM Step 2: Countermeasures for SOCs & HTAs

Objective:  Countermeasures for SOCs and HTAs

Stated in other words:

  • Prevent causes of dust, dirt, and leakage
  • Improve places that are difficult to clean, inspect, and lubricate
  • Reduce the time required for cleaning, inspection, and lubrication

AM Step 2 Sub-sections

Step 2 Activities:

  1. Countermeasures to SOCs
  2. Countermeasures to HTAs
  3. Implement Visual Controls

Sub-section 1: SOCs

  1. Identify Source Of Contamination
  2. Controllable vs. Uncontrollable contaminations
  3. Eliminating for controllable contaminations
  4. Create “Catch pan, localized covers” for uncontrollable contaminations.

Sub-section 2: HTAs

  1. Identify Hard To reach Area
  2. Countermeasures for HTAs
  3. Visual Control

Sub-section 3: Breakdown Analysis


AM Step 2.1 – Identify SOCs


  • Develop a list of SOCs if not complete from Step 1
  • Use the SOC List generated from the AM Step 1 “Four Lists” activity
  • Use F-Tags to continue to identify SOCs (Track them on F-Tag Centre)

AM Step 2.2 – Categorizing SOCs


  • To Categorize the list of SOCs:
    • Controllable vs. Uncontrollable (see next slide)
    • Then as A, B, C priorities (High/Med/Low)
    • Then follow the ECRS methodology (see next)
  • Use the SOC list from AM Step 1 and mark each SOC as A/B/C priority and Controllable vs. Uncontrollable

Controllable vs. Uncontrollable


These SOCs are within the team’s scope of control.


These SOCs are outside the team’s scope of responsibility

NOTE: Work on Controllable SOCs first!

ECRS Methodology


  • A quick method to develop countermeasures for SOCs & HTAs:
    • Eliminate
    • Combine
    • Replace
    • Simplify

ESCR is a tool to facilitate the development of countermeasures for SOCs. Ideally, all SOCs would be eliminated. At a minimum, SOCs are simplified.

ECRS Methodology Examples


  • Eliminate – outright removal of the SOC

Ex. Install a “No-dump” sensor for missing pouches

  • Combine – multiple SOCs into a single SOC

Ex. Combine the waste streams under the machine into a single catch-bin (vs. many today)

  • Replace – “Catch pan” to treat it easier

Ex.  Specific catch pan for mix, noodles, etc to recycle them

  • Simplify – the time required to manage the SOC

Ex. Install “catch-bins” under Bartelts to collect spillage

Countermeasures for SOCs Form

Countermeasures for HTA

A spreadsheet version of the form can be downloaded here



Temporary SOLUTION

Place slip sheet under source to catch debris

SOC Countermeasure

  • Replace the temporary slip sheet with a stainless manufactured version
  • Design change – increase the angle and funneling down to a bucket


  • Reduces time to clean
  • Eliminate the use of compressed air, dust exposure

AM Step 2.3 – Controllable SOCs

For Controllable SOCs:

  • All Controllable SOCs should be Eliminated (ideal scenario)
  • In this step, we implement the countermeasures for Controllable SOCs first

AM Step 2.4- Identify HTAs


  • Develop a list of HTAs if not complete from Step 1
  • Use the HTA List generated from the AM Step 1 “Four Lists” activity
  • Use F-Tags to continue to identify HTAs (Track them on F-Tag Centre)

AM Step 2.5 – Eliminate HTAs


  • Prioritize the list of HTA as A, B, C categories and then follow the ECRS methodology
  • Aim to eliminate the most critical (results-oriented) HTAs for cleaning, inspection, and lubrication

AM Step 2.6 – Visual Controls


  • Implement Visual Controls for cleaning, inspection, and lubrication points

– eg. Mark the “green and red” zone on the gauges existing on the line

– eg. Mark the inspection point for a sheet of Lexan that was installed

Example of Visual Controls: Operating range in gauges

AM Step 2.7 – Temporary Standards


  • Develop a temporary standard for Lubrication (very basic at this point)
  • Modify the temporary Cleaning standard that was developed from AM Step 1 considering the improvements generated after SOC and HTA countermeasures are in place.

Lubrication Standard

AM Step 2.8: Step Audit

AM Step 2.9 – Breakdown Analysis


  • Use the FI process to eliminate Breakdowns

AM Step 2 Flow

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