Tools

The Key Tool for Executing Continuous Improvement 12 Step Kaizen is a Better Defined CAP-Do Check Identify where the losses areJustify the subject selection by stratifying the dataUnderstand the process and equipmentGrasp the actual situation (Identify the Phenomenon)Establish the objectiveEstablish a Work Plan Analyze Determine Root Cause Plan Propose Countermeasures…

Let’s review an example of Breakdown Analysis of the failure that occurred in real life in the material handling department of a manufacturing factory: Step 1. 5W+1H and Phenomenon Summary Start your Breakdown analysis by answering six simple questions: 5 whys and 1 how Phenomenon Summary Use all answers from…

Section 1 5 WHY Process Causes of Losses are Often Complicated: Common Failure scenario: 1. Management system breakdown2. Failure to implement countermeasures3. Premature equipment failure4. Employees fail to follow the procedure5. Failure to ID & Respond6. Large Loss Results 5 Why Analysis is Proactive Addresses the Underlying Causes of Losses:…

What is Poka-Yoke? Developed by Toyota Motors as a tool to achieve Zero Defects Originally called Baka Yoke (idiot proof) but recognized that this label could offend workers so changed to Poka-Yoke (Mistake Proofing) One serious obstacle to extending equipment life is the unexpected failure that occurs as a result…