Kaizen Training. 6 Step Approach

Transcription

1 Kaizen Training 6 Step Approach

2 - - KAIZEN IS A STRUCTURED AND PROVEN PROBLEM SOLVING APPROACH WORKING EVERYWHERE 1a. PROBLEM DEFINITION 1b. QUANTIFICATION OF PROBLEM Conclusion from quantification analysis: Solving issue 1 would address X% of non-productive time Description of problem to solve: Current outcome: Target outcome: What is excluded from the solution space : Nonproductive time Issue 1 Issue 2 Issue 3 Issue 4 Issue 5 1 Define e problem and objectiveses 5. PROGRESS UPDATE Period: Action Solution A2: Action A2.1: Action A2.2: Solution B1: Action B1.1: Action B1.2: Status Main highlights since last review Main challenges 5 Implement 6 Check and make sustainable? M M 2 Analyze the facts 2a. ROOT CAUSE ANALYSIS THE FISHBONE Man Machine Environment 2b. RANKING OF CAUSES Conclusion from ranking: Addressing causes A, B, C would solve X% of the issue % of inefficiency caused M M Method Material Cause A Cause B Cause C Cause D Cause E Cause F Cause G 4. IMPLEMENTATION PLAN 4 Plan Generate potential solutions 3a. IDENTIFICATION OF SOLUTIONS Root cause Possible solutions (title and brief description) Action Solution A2: Action A2.1: Action A2.2: Responsible Name Start date Date End date Date Completed? Name Date Date Get approval Cause A Cause B Solution A1 Solution A2 Solution A3 Solution B1 Solution B2 Solution B1: Action B1.1: Action B1.2: Name Name Date Date Date Date Cause C Solution C1 Solution C2 Solution C3 Solution C4 3c. SOLUTIONS APPROVAL TEMPLATE 3d. APPROVALS PLAN Solution title B1. Brief description Expected impact Required investment Time until capturing impact Who needs to approve By when Who is responsible for getting the approval Approval received 3b. PRIORITISATION OF SOLUTIONS Do it soon A2. Igor Boševski 16 June 2007 John Smith Do if there is Plan time B2. C2. C4. A1. Impact Low High Do it soon Plan A2 B2 B1 C2 C4 Do if there is time Skip A3 C1 A1 C3 Legend (explanation of symbols) A1: A2: A3: B1: B2: C1: C2: C3: C4: 1 Low Effort High

3 STOPPING THE BLAME GAME Focus on problem itself, not who caused it 2

4 1 PROBLEM DEFINITION Statement: Non Value Added time is 40% Bad Example: Reduce the non value added time Good Example: Reduce the non value added time due to walking from 2 hours per shift to 0,5 hours per shift within one month KEY CRITERIAS - Describe problem specificly - Give Target - Give deadline 3

5 1a. PROBLEM DEFINITION Description of problem to solve: Current outcome: Target outcome: What is excluded from the solution space : 4

6 1b. QUANTIFICATION OF PROBLEM Conclusion from quantification analysis: NVA time 5

7 ROOT CAUSE ANALYSIS WITH THE 5 WHY s 1. Why did the machine stop? Bearing is overheated! Man 2. Why is the bearing overheated? Has too little oil! 3. Why too little oil? Pump doesn t supply enough oil! 4. Why doesn t the pump supply enough oil? The filter is fouled! 5. Why is the filter fouled? Maintenance interval too long! Root cause of the problem 6

8 2a. ROOT CAUSE ANALYSIS THE FISHBONE Man Machine - - NVA time Method Material 7

9 2b. RANKING OF CAUSES Conclusion from ranking: % of NVA time caused Cause A Cause B Cause C Cause D Cause E Cause F Cause G 8

10 3 SOLUTION DEVELOPMENT Speed fast / impact high Speed slow / impact low Problem Primary cause Fifth cause Countermeasures Speed of implementation Impact Excessive time for cleaning to remove rusts Man Inspection criteria is inconsistent among inspectors High variation of criteria in determining the occurrence of rust Lack of approved sample to be compared or applied Manufacture samples and approve Machine Lack of ant-rust facilities on the shop floor Anti-moisture indoor shop Cleaning brush is easily broken. Material is not flexible and easily erodable Use elastic and antierodable material Tool is not suitable. The drill for manual work is revamped Material A lot of holes and thick T/S Carbon material is exposed Close holes when cleaned up Rust may easily reoccur Contact with water when removing oil Change chemicals use in removing oil Method Rust can not be removed manually Lack of automatic tool for exclusive use Develop tools for exclusive use A lot of dust created Apply tool using air 9

11 3 SOLUTION DEVELOPMENT 1 If you do a good root cause analysis, then you can easily develop solutions Problem Primary cause Fifth cause Countermeasures Speed fast / impact high Speed slow / impact low Speed of implementation Impact Excessive time for cleaning to remove rusts Man Inspection criteria is inconsistent among inspectors High variation of criteria in determining the occurrence of rust Lack of approved sample to be compared or applied Manufacture samples and approve Machine Lack of ant-rust facilities on the shop floor Anti-moisture indoor shop Cleaning brush is easily broken. Tool is not suitable. Material is not flexible and easily erodable The drill for manual work is revamped 2 Use elastic and antierodable material Prioritize the solutions based on impact and easiness Material A lot of holes and thick T/S Carbon material is exposed Close holes when cleaned up Rust may easily reoccur Contact with water when removing oil Change chemicals use in removing oil Method Rust can not be removed manually Lack of automatic tool for exclusive use Develop tools for exclusive use A lot of dust created Apply tool using air 10

12 THINK LONG TERM Implementing a Band-Aid A Band-Aid is a temporary solution, to contain a problem A countermeasure must address the root cause! 11

13 3a. IDENTIFICATION OF SOLUTIONS Root cause Cause A Cause B Possible solutions (title and brief description) Solution A1 Solution A2 Solution A3 Solution B1 Solution B2 Solution B3 12

14 3b. PRIORITISATION OF SOLUTIONS Do it soon Plan Legend (explanation of symbols) Impa act High B2 A2 Do if there is time A1 Skip B1 A1 A2 A3 B1 B2 B3 Low A3 B3 Low High Effort 13

15 3c. SOLUTIONS APPROVAL TEMPLATE Solution title Brief description Expected impact Required investment Time until capturing impact Do it soon A2 B2 A1 B1 Pla an Do if the ere is time A3 14

16 3d. APPROVALS PLAN Who is responsible for Who needs to approve By when getting g the approval Approval received 15

17 4. PLAN WITH APPROVAL Action 1 DEADLINE 2 RESPONSIBLE Approval received Order new pipe 16 Feb 2008 Maintenance Engineer Train new operator 10 Feb 2008 Supervisor Review SOP 12 Feb 2008 Team with Prod. Mgr. Approved by Igor Boševski 16

18 4. IMPLEMENTATION PLAN Action Responsible Start date End date Completed? Action A1.1 1 Name Date Date Action A1.2 Name Date Date Action B1.1 Action B1.2 Approved by Igor Boševski 17

19 STEP 5: IMPLEMENT THE SOLUTION STEP 6: SUSTAIN IMPLEMENT SUSTAIN TELL TRAIN MONITOR CHECK 18

20 5. PROGRESS UPDATE Period: Action Status Main highlights since last review Main challenges Action A1.1 Action A1.2 Action B1.1 Action B1.2 19

21 Problem Solving 20

22 Trees should be mathematical correct EXAMPLE? What is wrong? 1 Avoid double testing Examples QC QC tests for raw materials from other Company sites Reduce number of samples per batch + 2 Use random sampling Combine batches in one delivery from supplier to one batch for sampling Reduce costs of testing x Reduce number of tests + Reduce number of tests per sample 3 Install automatic testing in production 4 Reduce number of repeats + 5 Reduce number of independent tests Perform real-time measurement of selected parameters Establish robustness of test to eliminate doubletesting of samples Reduce aspiration level Reduce quality control cost + Reduce costs per test? 6 Eliminate activities 7 Increase efficiency Install data base to automatically coordinate process changes Replace newer technology Reduce costs of supporting tasks? 21 8 Eliminate activities 9 Increase efficiency Transfer test results electronically to external parties Create order database for tests outside regular supply chain (e.g., R&D)

23 Empty templates 22

24 1a. PROBLEM DEFINITION Description of problem to solve: Current outcome: Target outcome: What is excluded from the solution space : 23

25 1b. QUANTIFICATION OF PROBLEM Conclusion from quantification analysis: 24

26 2a. ROOT CAUSE ANALYSIS THE FISHBONE Man Machine - - NVA time Method Material 25

27 2b. RANKING OF CAUSES Conclusion from ranking: % of caused Cause A Cause B Cause C Cause D Cause E Cause F Cause G 26

28 3a. IDENTIFICATION OF SOLUTIONS Root cause Possible solutions (title and brief description) 27

29 3b. PRIORITISATION OF SOLUTIONS Do it soon Plan Legend (explanation of symbols) Low High Impa act Do if there is time Skip Low High Effort 28

30 3c. SOLUTIONS APPROVAL TEMPLATE Solution title Brief description Expected impact Required investment Time until capturing impact Pla an Do it soon Do if the ere is time 29

31 3d. APPROVALS PLAN Who is responsible for Who needs to approve By when getting g the approval Approval received 30

32 4. IMPLEMENTATION PLAN Action Responsible Start date End date Completed? 31

33 5. PROGRESS UPDATE Period: Action Status Main highlights since last review Main challenges 32