8 Step Problem Solving Method
• Deepen your awareness of the importance of the 8 step process to effective problem solving • Apply the process to your own work situation during class discussion • Experience how the A-3 tool communicates the process thinking • Apply in the work environment that will work both in the field and in the on-campus lab
Learning Goals 2
8 Step Problem Solving Process 8 Step Process for Problem Solving Steps Depth Zero level Go deeply on each step Complete
Step 1
Step 2
Step 3
Step 4 Root Cause
Step 5
Step 6
Step 7
Step 8 Toyota strength‐ standardize
3
1
Be adaptable to the work process needs-- take action quickly If necessary, use TEMPORARY measures -when a problem occurs, take action quickly
Keep at it until TRUE countermeasures are in place -that which if implemented prevents problem from returning
Speedy Action in a Timely Manner 4
Difference between “Temporary Measure" and “Countermeasures”
Problem
Why?
Machine over travels
Limit switch not activated (Fact)
Why ? Limit switch Arm is Frozen (fact)
(Temporary
measure) Replace the limit switch
Prevents the recurrence
Why?
Root Cause
Limit switch is in Coolant air flow
(Countermeasure) shield limit switch from coolant
Temporary Measure Example 5
Action to stop or contain the problem-can add necessary extra work to the process. ( + $ / + / + ) • When a problem occurs, take action quickly • Purpose is to contain the problem, not solve it.
Temporary Measure 6
2
Select the optimal containment action on the following criteria: • Simplicity • Minimal modification to current process • Time to implement Option 1 Simplicity Modification Time
10 9 10 29
Option 2
Option 3
8 7 10 5 9 7 27 17 Sum the score and select the option with the highest score
Rate each option relative to each other for each criteria
Short-Term Containment
7
Problem Identified C/M Identified C/M Implemented Follow up Complete
Temporary Measure Implementation Plan 8
A problem is … The current situation gap to the standard = PROBLEM • Fact based • Discovery driven Standard Gap = Problem Current Situation
What Defines a problem in the 8 Step method? 9
3
Non Value Added Work = Waste • Waste is any factor which does not contribute to the process by adding value. • The goal of Lean is to eliminate any factors which raise cost without adding value to the product.
What Defines a problem in the 8 Step Method? 10
Motion
Overproduction
Inventory Quality Defects
The 7 Wastes!
Waiting
Over Processing
Transportation
What Defines a problem in the 8 Step Method? 11
Would you like to work in this place?
What Defines a problem in the 8 Step Method? 12
4
See normal vs abnormal
After Racks and Containers for Small Lot
SOP
Andon Cord Andon Board Information Charts
Scoreboard 5-S
Safety Glasses On
Foot-printing Floor
Walking Aisle Ergo Aid Table
13 What Defines a problem in the 8 Step Method?
Step1.Clarify the Problem Step 2. Break Down the Problem
P
Step 3. Target Setting
Step 4. Root Cause Analysis Step 5. Develop Countermeasures
D
Step 6. See Countermeasures Through
C
Step 7. Monitor Both Results and Processes
A
Step 8. Standardize Successful Processes
8 Step Process for Problem Solving 14
• See handout
Example of Problem A-3 Report 15
5
Proceedings
8 Steps
Step 1. Clarify the Problem
(1) Clarify the “Ultimate Goal” of your responsibilities & work (2) Clarify the “Standard” of your work (3) Clarify the “Current Situation” of your work (4) Visualize the gap between the “Current Situation” and the “Standard”
Step 1 - Clarify the Problem 16
Visualize the gap between the “Current Situation” and the “Standard”
Defects
Problem The Standard
.5 .4 .3
The Current Situation
.2
Visualize the gap between the current situation and the standard
.1
Aug
Sep
Oct
Nov
Step 1 - Clarify the Problem 17
Process1. Clarify the “Ultimate Goal” of your responsibilities & work
Ultimate Goal
My job’s purpose
My work & Responsibilities
To provide customers with highly functional and high-quality cars at reasonable prices in a timely manner
To meet customer demand
To meet Production Plans
Step 1 - Clarify the Problem 18
6
1. Clarify the Problem Ultimate Goal: Assure TMMK cars meet customer requirement for quality Standard:
Zero audit defects from sealer area
Current Situation:
7 water leaks on 7/28 15 10
7
Gap=7 0
5
Example: Step 1
0 Actual
Standard
19
1. Clarify the Problem Ultimate Goal: TMs are compensated for work completed and paid timely and fairly Standard: 100% (3300) of TM’s paychecks are deposited error free Current Situation: 80% (2640) of TM’s paychecks are deposited error free
GAP 20% (600) paychecks Need a manual check To correct errors
100 80 60 40 20 0
3300
2640 Gap=(20%) 660
80%
100%
Current Standard
Example: Step 1 20
8 Steps Step 1. Clarify the problem
Step 2. Break down the problem
Proceedings (1) Clarify the “Ultimate Goal” of your responsibilities & work (2) Clarify the “Standard” of your work (3) Clarify the “Current Situation” of your work (4) Visualize the gap between the “Current Situation” and the “Standard”
(1) Break down the problem (2) Identify the prioritized problem (3) Specify the point of occurrence by checking the process through GENCHI GENBUTSU
Step 2 - Break Down the Problem 21
7
Big Problem
Problem
Problem
What Where When Who
Problem
NOT Why! Problem
Problem
Problem
Problem
Problem
Problem
Problem
Prioritized Problem
Prioritized Problem at the Point of Occurrence
Step 2 - Break Down the Problem 22
• Formulating a clear, concise statement from your Gap • The statement describes the difference between the standard and current situation • During this step, break the large problem into smaller, more specific problems • If you can’t describe it, you can’t solve it!
Step 2: Break Down the Problem 23
Narrow the problem sufficiently Classify and quantify 7 Water leaks
1 on Avalon
1 in Mohican
6 on Camry
Vehicle Type
1 side
Process
5 Tail light
Many water leaks in the tail light
Prioritized Problem
Priority decision: tackle the biggest impact problem FIRST
Step 2 - Break Down the Problem 24
8
3% increase in SCRATCHES found on vehicle at Final Inspection
Classify Then Quantify
Trunk=0% Trunk Left=95% Roof=0% Left Roof Right=5% Hood=0% Right Hood
Frt Door= 80%
RR Door= 15%
Fender=0%
Qtr Pnl= 5%
80% Window Frame
Prioritized Problem
15% Door Handle
5 % Side Pnl
Step 2 - Break Down the Problem 25
• The point of occurrence (POO) is the actual work element at the physical location where the problem is first seen • For example, walk the line back. Check each work station, until you arrive at the station where the problem is no longer seen 8 Step Problem Solving (Locate Point of Occurrence)
26
Standard Work Pick seat from back w/carrier
Set seat to car
Align seat to rail
Remove carrier
Shoot bolts
(POO) Defect was found here
Process steps
Scuffed / Damaged Cup Holder @ CSA
Scuffed / Damaged Cup Holder @ start of final
Scuffed / Damaged Cup Holder @ after Front seat install
No damage @ before Front seat install
Back track
Locate Point of Occurrence (POO) 27
9
Where is Point of Occurrence? Prioritized Problem at the Point of Occurrence
Why is Point of Occurrence important?
For efficient use of time & effort
Step 2 - Break Down the Problem 28
2. Break Down the Problem 7 Water leaks
1 on Avalon
1 in Mohican
6 on Camry
Vehicle Type
1 side
Process
5 Tail light Many water leaks in the tail light
Go and See Investigation for Point of Occurrence 1) Floor Brush--Finish lower seam on end panel Prioritized Problem
2) Engine Room Finish--Finsh the area just above and below the tail light Processes
Standard Work
1st Application
Engine Room
Finish Hood Corner
Trunk Brush
Floor Brush
Finish Rear Hood
Finish Mirror Plate
Finish Upper end panel
2nd Application
Finish Side tail light
Example: Step 2
Engine Room Finish
Point of Occurrence (POO)
Finish below tail light
Point of Occurrence
29
2. Break Down the Problem 20% (660/3300) manual checks being issued
Group Leader Error 35% (231/660)
Time Execution 61% (142/231)
Other 23% (151/660)
Other 39% (90/231)
Salary Continuation 42% (277/660)
STD Not Paid 30% (83/277)
FMLA PTO Not Paid 70% (193/277) Prioritized Problem
FMLA Process Flow
T/M obtains FMLA form
Point of Occurrence (POO)
T/M submits form to TMR by deadline
TMR reviews form - submits by deadline
Payroll system updated by deadline
T/M received paycheck with correct amount
Problem: FMLA paperwork is not received from TMR by the payroll deadline.
Example: Step 2 30
10
8 Steps Step 1. Clarify the problem
Step 2. Break down the problem
Step 3. Set a target
Proceedings (1) Clarify the “Ultimate Goal” of your responsibilities & work (2) Clarify the “Standard” of your work (3) Clarify the “Current Situation” of your work (4) Visualize the gap between the “Current Situation” and the “Standard” (1) Break down the problem (2) Identify the prioritized problem (3) Specify the point of occurrence by checking the process through GENCHI GENBUTSU
(1) Make a commitment (2) Set measurable, concrete and challenging targets
Step 3) Set a Target 31
Prioritized Problem Standard Problem
Big Problem Current Situation
Point of Occurrence
Target
Problem
Problem
Step 3 - Set a Target 32
3. Target Setting Target: Eliminate 5 tail light area water leaks on Camry by 7/29
Example: Step 3 33
11
3. Target Setting Target: Eliminate 100% late submissions of FMLA forms to meet payroll deadline by arch 2009. (193 of 660 total gap)
Example: Step 3 34
Example through Steps 1, 2, & 3 1. Clarify the Problem Ultimate Goal:
No waterleaks in TMMK produced cars
Ideal Situation (Standard):
Zero audit defects from Sealer area 15
Current Situation:
7 waterleaks on 7/28
10
7
5
Gap = 7 Goal
Actual
2. Break Down the Problem 7 Water leaks
1 on Avalon
6 on Camry
1 in Mohican
5 Tail light
Vehicle Type
Process
1 side
Many water leaks in the tail light
Prioritized Problem
Go and See Investigation for Point of Occurrence 1) Floor Brush--Finish lower seam on end panel 2) Engine Room Finish--Finsh the area just above and below the tail light 1st Application
Engine Room
Floor Brush
Trunk Brush
2nd Application
Finish Hood Corner
Finish Rear Hood
Finish Mirror Plate
Finish Upper end panel
Finish Side tail light
Engine Room Finish
Finish below tail light
Point of Occurrence
3 5
3. Target Setting Target: Eliminate 5 tail light area water leaks on Camry by 7/29
3 1. Clarify the Problem Ultimate Goal: TMs are compensated for work completed and paid timely and fairly
3300
100 80 60 40 20 0
Standard: 100% (3300) of TM’s paychecks are deposited error free Current Situation: 80% (2640) of TM’s paychecks are deposited error free
2640 80%
Gap=(20%) 660 100%
Current Standard 2. Break Down the Problem 20% (660/3300) manual checks being issued
Group Leader Error 35% (231/660) Time Execution 61% (142/231)
Other 39% (90/231)
FMLA Process Flow T/M obtains FMLA form
T/M submits form to TMR by deadline
Other 23% (151/660)
Salary Continuation 42% (277/660) STD Not Paid 30% (83/277)
FMLA PTO Not Paid 70% (193/277) Prioritized Problem Point of Occurrence (POO) T/M received TMR reviews Payroll system paycheck with form - submits updated by correct amount by deadline deadline
Problem: FMLA paperwork is not received from TMR by the payroll deadline. 3. Target Setting
Target: Eliminate 100% late submissions of FMLA forms to meet payroll deadline by March 2009. (193 of 660 total gap) 36
12
Example through Steps 1, 2, & 3
37
8 Steps Step 1. Clarify the problem
Step 2. Break down the problem
Step 3. Set a target
Step 4. Analyze the Root Cause
Proceedings (1) Clarify the “Ultimate Goal” of your responsibilities & work (2) Clarify the “Standard” of your work (3) Clarify the “Current Situation” of your work (4) Visualize the gap between the “Current Situation” and the “Standard” (1) Break down the problem (2) Identify the prioritized problem Specify the point of occurrence by checking the process through GENCHI (1)(3) Make a commitment GENBUTSU (2) Set measurable, concrete and challenging targets
1) Examine the Point of Occurrence and think of possible causes without prejudice (2) Gather facts through GENCHI GENBUTSU and keep asking “Why?” (3) Specify the root cause
Step 4 - Analyze the Root Cause 38
Time for WHY
Prioritized Problem at the Point of Occurrence
Possible cause
Possible cause
Possible cause
Possible cause
Not a fact
Not a fact
Not a fact
Fact
Possible cause
Possible cause
Possible cause
Not a fact
Not a fact
Fact
Possible cause
Not a fact
Think of all meaningful possible causes
Go and See to confirm
Possible cause
Repeat
Fact
Root cause
Step 4) Analyze the Root Cause 39
13
(Example) Bad polishing of painted parts Man (Human): Standard work being followed? Machine: RPMs correct? Material: Correct compound? Method: Polishing standard correct? Environment: Work place temperature correct?
Step 4 - Analyze the Root Cause 40
Example:
Welding robot stops in the middle of its operation.
Why? A fuse in the robot has blown. Why? Circuit overloaded. Why? The bearings have damaged one another and locked up. Why? There was insufficient lubrication on the bearings. Why? Oil pump on robot is not circulating suffi Why? Pump intake is clogged with metal shavings. Why? No filter on pump intake (as designed)
Root Cause
Step 4 - Analyze the Root Cause 41
4. Root Cause Analysis Waterleaks on the left side tail light T/M leaving gaps in finish T/M not turning spatula into the seam T/M not instructed in proper angle of finish when trained No specification in STW for proper spatula angle when finishing
ROOT CAUSE
*Apply the “therefore” test to check thinking
Example through Step 4
Step 4 - Analyze the Root Cause 42
14
4. Root Cause Analysis FMLA paperwork is not received from TMR by the payroll deadline Form doesn't pass review Form was submitted incorrectly Part "D" not complete T/M thought HR was to complete Instructions not clear in Part "D"
*Apply the “therefore” test to check thinking
Example through Step 4
Step 4 - Analyze the Root Cause 43
Example Step 4 44
8 Steps
Proceedings
Step 1. Clarify the problem
Step 2. Break down the problem
(1) Clarify the “Ultimate Goal” of your responsibilities & work (2) Clarify the “Standard” of your work (3) Clarify the “Current Situation” of your work (4) Visualize the gap between the “Current Situation” and the “Standard” (1) Break down the problem
Step 3. Set a target
(2)Make Identify the prioritized problem (1) a commitment (3)Set Specify the point of occurrence by checking (2) measurable, concrete and challenging targets the process through GENCHI GENBUTSU
Step 4. Analyze the root cause (1) Examine the point of occurrence and think of possible causes without
(1)prejudice Develop as many potential countermeasures
Step 5. Develop countermeasures
(2) Gather through GENCHI GENBUTSU and keep asking “Why?” as facts possible (3) Specify the root cause (2) Select the highest value added countermeasures (3) Build consensus with others (4) Develop a clear and detailed action-plan
Step 5) Develop Countermeasures
45
15
Procedure for developing countermeasures Countermeasure Countermeasure Countermeasure
Root Cause
Countermeasure Countermeasure with the highest value-added Countermeasure Countermeasure Countermeasure
Step 5 - Develop Countermeasures 46
Select the highest value added Countermeasures Evaluate all potential Countermeasures Effectiveness
Truly eliminates the Root Cause Meets the Target
Cost/Manpower
The cost and time Number of people required to implement/to sustain
Risk
The risks when implementing Safety? Quality? Workability? Impact on other previous or following processes
Step 5 - Develop Countermeasures 47
Build consensus with others Present to management for approval to go forward— A-3 format is a standardized and efficient tool •Explain and discuss plans with all relevant parties • Set up a cross functional committee • Organize the meeting to present the analysis and countermeasure ideas/plans • Hold update meetings to share latest info/progress Note: thru Process step 5, planning phase is completed
Step 5 - Develop Countermeasures 48
16
Select the highest value-added Countermeasures Make an evaluation matrix: Countermeasure for assembling mismatched parts Risk Overall judgment
Workability
Problems to other processes
Safety problem
Quality problem
Technical difficulty
Expected effort
Options
Cost / Man-hour
Factors
Change parts color Change parts shape
X X X
X
X X
Good Acceptable
Change sequence of operation
NG Optimal
Confirm the facts by interviewing related people and departments
Step 5 -Develop Countermeasures 49
Develop a clear and detailed action-plan When creating the action-plan, be sure to clearly identify the four W’s of the countermeasures Who – What – Where – When? Clarify the roles and responsibilities of people and departments involved
Keep updates (point to be checked) through reporting, informing, and consulting
Clarify the schedule and order of actions to implement
(Example)Action Plan Action items Determine the best color for parts per model
Operator
A
July August September 1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W Discuss color Discuss and decide in a team meeting
Request to prepare Prepare trial parts
Test by using trial parts
B
Confirm test results Report to managers
Step 5 - Develop Countermeasures 50
5. Develop Countermeasure R.C. No spec in standard work for spatula angle Cost
Safety
Add inspection process
∆
∆
O
∆
∆
Train T/M's in correct angle to hold spatula
Effort
∆
O
O
Effectiveness
O
Overall
O
Repair in CART
X
X
O
X
X
Temp Action Add inspection key points at quality gate and feeback to T/M's ‐ 7/28
Make a Plan
Example: Step 5 51
17
5. Countermeasure Options & Evaluation Options
Effectiveness
Budget
Speed
Quality
Overall Assessment
Post clearer instructions on T/M board
X
O
O
X
X
O
O
O
O
Update instructions on form Have TMR instruct T/M Update instructions on form along with TMR communications
O
O
Comments -Create awareness of enhancement -Help T/Ms who review board -Not helpful at home -Would document enhancement as new standard -Dependent on T/M reading it -Verbally communicate the enhancement -Cannot ensure that T/M will remember the instructions if not written down
O
O
-Would document enhancement as new Standard while confirming the instructions
Example: Step 5 52
8 Steps Step 1. Clarify the problem
Step 2. Break down the problem
Step 3. Set a target Step 4. Analyze the root cause
Step 5. Develop countermeasures
Proceedings (1) Clarify the “Ultimate Goal” of your responsibilities & work (2) Clarify the “Standard” of your work (3) Clarify the “Current Situation” of your work (4) Visualize the gap between the “Current Situation” and the “Standard” (1) Break down the problem (2) Identify the prioritized problem (3) Specify the point of occurrence by checking the process through GENCHI GENBUTSU (1) Make a commitment (2) Set measurable, concrete and challenging targets (1) Examine the point of occurrence and think of possible causes without prejudice (2) Gather facts through GENCHI GENBUTSU and keep asking “Why?” (3) Specify the root cause (1) Develop as many potential countermeasures as possible (2) Narrow down the countermeasures to the most practical and effective (3) Build consensus with others (4) Develop a clear and detailed action-plan
Step 6 - See Countermeasures Through 53
8 Steps Step 6. See countermeasures through
Proceedings (1) With all members united, implement countermeasures with speed and persistence (2) Share information with others by informing, reporting and consulting (3) Never give up, and proceed to the next step quickly
Step 6 - See Countermeasures Through 54
18
Implement Countermeasures with speed and persistence after consensus (Nemawashi) building
1) Concentrate efforts 2) Check progress regularly “On-the-floor” standup at the progress boards— relate to “jishuken” room
Step 6) See Countermeasures Through 55
6. See Countermeasure Through Countermeasure Plan - Train T/M's in correct spatula angle
What
Who
When
Status
Rewrite Standard Work
T/L
7/28
100%
Develop SWES with Key Points
T/L
7/29
100%
Train T/M's
T/L
7/30&31
100%
Check for 3 Shifts
T/L
8/3
100%
Remove Temp Action
T/L
7/30
100%
Additional tracking method -
100%Complete
25% Complete
75% Complete
50% Complete
Example: Step 6 56
6. Action Plan Item (What) (When)
Resp (Who)
Timing Feb W1
Draft form with clearer instructions
W2
W3
Mar W4
W1
W2
W3
W4
TH
Sample T/M response; revise as needed
TH
Consensus/Approval throughout HR
RK
Coordinate communication method with TMR and roll out
SE
Example: Step 6 57
19
Good Acceptable NG Optimal
Example through Steps 5 & 6 58
8 Steps Step 1. Clarify the problem
Step 2. Break down the problem
Step 3. Set a target Step 4. Analyze the root cause Step 5. Develop countermeasures
Proceedings (1) Clarify the “Ultimate Goal” of your responsibilities & work (2) Clarify the “Standard” of your work (3) Clarify the “Current Situation” of your work (4) Visualize the gap between the “Current Situation” and the “Standard” (1) Break down the problem (2) Identify the prioritized problem (3) Specify the point of occurrence by checking the process through GENCHI GENBUTSU (1) Make a commitment (2) Set measurable, concrete and challenging targets (1) Examine the point of occurrence and think of possible causes without prejudice (2) Gather facts through GENCHI GENBUTSU and keep asking “Why?” (3) Specify the root cause (1) Develop as many potential countermeasures as possible (2) Narrow down the countermeasures to the most practical and effective (3) Build consensus with others (4) Develop a clear and detailed action-plan
Step 7 - Evaluate Both Results and Processes 59
8 Steps Step 6. See Countermeasures Through
Step 7. Evaluate Both Results and Processes
Proceedings (1) With all members united, implement countermeasures with speed and persistence (2) Share information with others by informing, reporting and consulting (3) Never give up, and proceed to the next step quickly
(1) Evaluate the results and the processes, and share it with members involved (2) Evaluate from three key perspectives: Customer’s, 8 Step’s, and Your Own (3) Understand the reasons of success and failure
Step 7 - Evaluate Both Results and Processes 60
20
Evaluate results and process, and share it with stakeholders Evaluate the process for achieving the results Did we analyze the true root cause?
What was most effective?
Did we follow the Problem solving 8 steps completely?
Step 7 - Evaluate Both Results and Processes 61
Evaluate results and processes, and share it with stakeholders
Confirm positive and negative effects
Positive effects Repair hours
Achieved target Negative effects
Cost for machine modification
Step 7 - Evaluate Both Results and Processes 62
Develop a tracking chart or graph (make the standard/target easy to see • Where do we get the data? • What data is needed? • What is the required time period? • Who will collect and summarize data?
Step 7 Execution 63
21
7. Monitor Both Results and Processes Tail light Waterleak Tracking 7/28
8 defects
7/29
0 defects
7/30
0 defects
7/31
0 defects
8/1 8/2
0 defects 0 defects
8/3
0 defects
Tail Light Waterleaks
Remove Temp Action
10 8 6 4 2 0
# of defects 7/28
7/29 7/30 7/31 8/1 8/2 8/3 Date
Example: Step 7 64
7. Monitor Both Results and Processes Number of FMLA forms from TMR not meeting payroll deadline
250 200
193
150 100
100
98
W2
W3
50
20
19
W4
May W1
6
0
W2
W3
0 April W1
Example: Step 7 65
8 Steps Step 1. Clarify the problem
Step 2. Break down the problem
Step 3. Set a target
Step 4. Analyze the root cause
Step 5. Develop countermeasures
Proceedings (1) Clarify the “Ultimate Goal” of your responsibilities & work (2) Clarify the “Standard” of your work (3) Clarify the “Current Situation” of your work (4) Visualize the gap between the “Current Situation” and the “Standard” (1) Break down the problem (2) Identify the prioritized problem (3) Specify the point of occurrence by checking the process through GENCHI GENBUTSU (1) Make a commitment (2) Set measurable, concrete and challenging targets (1) Examine the point of occurrence and think of possible causes without prejudice (2) Gather facts through GENCHI GENBUTSU and keep asking “Why?” (3) Specify the root cause (1) Develop as many potential countermeasures as possible (2) Narrow down the countermeasures to the most practical and effective (3) Build consensus with others (4) Develop a clear and detailed action-plan
Step 8 - Standardize Successful Processes 66
22
8 Steps Step 6. See Countermeasures Through
Step 7. Evaluate Both Results and Processes
Step 8. Standardize Successful Processes
Proceedings (1) With all members united, implement countermeasures with speed and persistence (2) Share information with others by informing, reporting and consulting (3) Never give up, and proceed to the next step quickly
(1)Evaluate the results and the processes, and share it with members involved (2)Evaluate from three key perspectives: Customer’s, 8 Step’s, and Your Own (3)Understand the reasons of success and failure
(1) Set successful processes as new standard (2) Share the new standard (YOKOTEN) (3) Start the next round of KAIZEN
Step 8 - Standardize Successful Processes 67
Procedure for Standardizing successful processes (1) Successful processes as new standard Overall Company Own work area
(2) Share the new standard (YOKOTEN)
Ideal Situation
KAIZEN Standardization
(3) Start the next round of KAIZEN
YOKOTEN
KAIZEN Standardization
YOKOTEN
KAIZEN
Success
Standardization
YOKOTEN
Implementation
Step 8 - Standardize Successful Processes 68
Start the next round of KAIZEN Kaizen Standardize Solve one problem Repetition of problem solving process
KAIZEN KAIZEN KAIZEN
Step 8 - Standardize Successful Processes 69
23
8. Standardize Successful Processes Yokoten: Contact other NAMC's to confirm no problem Follow-up: Have Pilot add special check for finish angle in Standardized work development
Example: Step 8 70
8.
Standardize Successful Performance
Document reason for adding additional instructions to form Standardize electronic form in database with revision date Yokoten: Share the new form with other NAMCs by June 30
Example: Step 8 71
5. Develop Countermeasure
1. Clarify the Problem Ultimate Goal:
No waterleaks in TMMK produced cars
R.C. No spec in standard work for spatula angle Effort
Zero audit defects from Sealer area
Ideal Situation (Standard): Current Situation:
7 waterleaks on 7/28
10
∆
Effectivenes s
Ove rall
O
∆
∆
O
O
O
O
X
X
O
X
X
Temp Action Add inspection key points at quality gate and feeback to T/M's ‐ 7/28
Gap = 7 Actual
∆
Safety
∆
Repair in CART
7
5
Cost
Train T/M's in correct angle to hold spatula
Add inspection process 15
Goal
2. Break Down the Problem
6. See Countermeasure Through 7 Water leaks
1 on Avalon
Countermeasure Plan - Train T/M's in correct spatula angle
6 on Camry
1 in Mohican
5 Tail light
1 side
Vehicle Type
Many water leaks in the tail light
What
Who
Rewrite Standard Work
T/L
Develop SWES with Key Points
When
Status
7/28
100%
T/L
7/29
100%
Train T/M's
T/L
7/30&31
100%
Check for 3 Shifts
T/L
8/3
100%
Remove Temp Action
T/L
7/30
100%
Process Prioritized Problem
C/M Complete
C/M Identified
C/M Tracking
C/M Implemented
Go and See Investigation for Point of Occurrence 1) Floor Brush--Finish lower seam on end panel 2) Engine Room Finish--Finsh the area just above and below the tail light Engine Room
Floor Brush
Trunk Brush
2nd Application
Finish Hood Corner
Finish Rear Hood
Finish Mirror Plate
Finish Upper end panel
Finish Side tail light
7. Monitor Both Results and Processes Engine Room Finish
Tail light Waterleak Tracking
Finish below tail light
Point of Occurrence
3. Target Setting
7/28
8 defects
7/29
0 defects
7/30
0 defects
7/31
0 defects
8/1
0 defects
8/2
0 defects
8/3
0 defects
Tail Light Waterleaks
# of defects
1st Application
Remove Temp Action
10 8 6 4 2 0
7/28
7/29 7/30 7/31 8/1 8/2 8/3 Date
Target: Eliminate 5 tail light area water leaks on Camry by 7/29
8. Standardize Successful Processes
4. Root Cause Analysis
Yokoten: Contact other NAMC's to confirm no problem
Waterleaks on the left side tail light T/M leaving gaps in finish T/M not turning spatula into the seam
Follow-up: Have Pilot add special check for finish angle in Standardized work development
T/M not instructed in proper angle of finish when trained No specification in STW for proper spatula angle when finishing
ROOT CAUSE
Example: Steps 1-8 72
24
Example: Steps 1-8
73
Example: Steps 1-8 74
25