Problem Solving REAL WORLD . roblem Solving REAL WORLD . Problem Solving
Problem Solving 5 Why[1]
Transcript of Problem Solving 5 Why[1]
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Volvo Construction Equipment
Construction Equipment 1
Sean O¶Dea
Supplier Development Eskilstuna 1st ± 3rd February
Problem solving 5 Why
Background
8D
Case Study 5 Why
Case Study
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Volvo Construction Equipment
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Supplier Development Eskilstuna 3rd February
Is there a clear joint plan toachieve the project targets ?
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Volvo Construction Equipment
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Global Supplier Development
Design & Development
Phase 1
SD Responsibility: Feed in know how Project Kick off, Define responsibilities, strategies and top level timing Plan
Fix, Who will do what, why and when.
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Draft Lead-timePriority
1
23
E n g i n e
e r i n g
Basic Change List
SEM.Supplier Selection
QDC& E
Focus partsList
New SuppliersStrategic Suppliers
Long Lead TimeUnique specification
High process costs
Past Problem ListProcess
Feed back from Mass
Production
Critical problems only
Technical Challenge
P u r c h a s e
S u p p l i e r D e v e l o p m e n t
Joint Development Plan
( Who, What and When )RTSVA VEP
re IPP
SSpecification test -schedulesPrototype production.
Drawing issue DatesDraft Process flows.
Is there a clear joint plan to Achieve the project targets ?
Project gateway
Purchase. C. Cost Target
Q Known Problems prevented
D. Lead time achievable
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Critical
Problem
Check
sheet
A Rank must be
Fed forward
Problem RecordInspection reports, 8D, etc
A Q u a n t i t y
A Rank. High Disturbance Stopped production, only found at PDIHigh Repair time. Functional or Safety problem. Potential for fieldoccurrence
BB Rank. Medium Disturbace. Found at Assy. Repair on line,
Did not stop the line
C
C Rank. Low Disturbance Found before Assy, No disruption toproduction, Issue for supplier information
Focus SD resource on Critical issues µ High effect on customer¶
Feed Forward Problem selection, Ranking.
Global Supplier Development
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Project Plan
Control Plan( Quality Contract )
Define Process Flow
Control parameters& measurement frequency
P-FMEA
Evaluate & Reduce Risk
Of producing NG PartsSuppliers experience
Past problems
Process Design.
DWG / Spec considerations
Specification
DRG
Process Flow0²0
I0---o²o---O
V o l v o
S u p p l i e r
Process that can makethe parts, with optimum
QD and C
ProcessInstruction
Check sheets
&Records
Part Requirements
Enough for QA check.
Sequenced µhow to do¶¶ define what is important
Volvo PQAP Requirements ( stage 2 )
Critical
ProblemChecksheet
Past problemsProcess Design.
DWG / Spec considerations
Global Supplier Development
Clear understanding of problem cause
and countermeasure required
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K now How Collection
± 8D Approach Example
Case Study 40 mins
Supplier Development Eskilstuna 2nd February
Clear understanding of problem cause
and countermeasure required
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123 15 Jan 2005
123
AB Silencer
Sean O¶Dea
1
Xyz 123
Muffler
QA 1
1
202
Poor Weld condition on Muffler
X
Quality Manager
Jan 2005
Jan 2005
Check all parts Inform Dispatch Inspectors, Issue Quality Alert
Quality Manager
Jan 2005
Jan 2005
Quality Manager
Jan 2005
Jan 2005
Quality Manager
Jan 2005
Jan 2005
Blue pen mark to show 200% inspection Green Dot on container labels
16 Jan
All parts have been checked, NO further poor weld parts found
X
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Poor dispatch inspection. No visual aid to help judge OK and NOK Parts
Quality Manager
Jan 2005
Jan 2005
Quality Manager
Jan 2005
Jan 2005
Quality Manager
Jan 2005
Jan 2005
Quality Manager
Issue Visual Aid showing OK and NOK part condition
Inspectors have been trained Visual Aid in position on shop floor at inspection station.
200 % Inspection to continue for next Batch
SEAN O¶DEA
2524
16 Jan 2005
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123 18 Jan 2005
123
AB Silencer
Sean O¶Dea
1
Xyz 123
Muffler
QA 1
1
202
Poor Weld condition on Muffler
X
Quality Manager
Jan 2005
Jan 2005
Check all parts Inform Dispatch Inspectors, Issue Quality Alert
Quality Manager
Jan 2005
Jan 2005
Quality Manager
Jan 2005
Jan 2005
Quality Manager
Jan 2005
Jan 2005
Blue pen mark to show 200% inspection
Green Dot on container labels16 Jan
All parts have been checked, NO further poor weld parts found
X
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Weld parameters not sufficient, current settings were too lowTo effectively allow continuous weld arc.
Jan 2005
Jan 2005
Production Manager
Jan 2005
Jan 2005
Jan 2005
Jan 2005
Quality Manager
Weld parameter µAmps¶ increased and wire feed speed adjustedTo maximum level. Mark added to µAmps¶ dial to show required position when welding
Volvo parts.
With weld Amps set to maximum there is no chance of abrake in the weld arc.
200 % Inspection to continue for next Batch
SEAN O¶DEA
2524
16 Jan 2005 15 Jan 2005
Production Manager
Production Manager
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Case Study Material
Issue 1 and Issue 2 8D
Volvo initial info ( fax IR )
Muffler cell layout
Muffler weld machine Process flow and Control Plan
Process Instructions
Supplier Initial analysis
Process rejection Data
Receiving inspection Certificate of Conformance
Receiving inspection reports
Sub Assembly jig report
Muffler training matrix
What data / Information do you need ?
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K now How Collection
± 5why Approach Format & Purpose
Example
Case Study 40 mins
Supplier Development Eskilstuna 2nd February
Clear understanding of problem cause
and countermeasure required
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5 Why Problem solving Tool
µ5Why¶ Talked about, but not standardised
µ5Why¶ difficult to perform without experience & guidance
Volvo CE have limited experience of 5Why, suppliers have less
5Why requires fact based analysis.
Purpose. To drive analysis to identify root cause, If root cause is
not established problem will not be countermeasured, justsymptom. Actioning symptom can lead to new problems and
higher costs. ( Adding processes and manpower )
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5 Why Problem solving Tool
Supplier Development Eskilstuna 2nd February
Problem. A man has a headache.
Countermeasure. Take a headache tablet
Problem re-occurrence . The man has another headache.
Countermeasure. Take a stronger headache tablet ?
Gather data that effects head aches.
± Change in conditions, operating environment
± Specification analysis, blood pressure, blood sugar levels, vision tests.
± When does problem occur. Morning after party, after reading, after
exercise, when I have an SD meeting.
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5 Why Problem solving Tool
Shortcut to 5 why BLANK.lnk
Supplier Development Eskilstuna 2nd February
Problem. A man has a headache.
Why ? Blood pressure is too high
Why? Cholesterol level too high
Why? Diet is not balanced ( Each chips with every meal )
Why? No information of correct diet
Why? Not understood to be a problem Countermeasure. Set diet standard and regularly
monitor
Shortcut to 5 why explanation.lnk Shortcut to 5 why.lnk
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5 Why Example.
R oot cause can not be established withcurrent data !!
Supplier Development Eskilstuna 2nd February
Potentials
± Scrap or rework part sent in error
± Machine Belt slipping
± Incorrect initial settings
± Part not installed correctly ( Poor machine cleanliness )
± Part slipping due to spring pressure
± Part slipping due to part length ( Too Short ) ± Child part size variance. Too big
± Etc. etc.
Further investigation with supplier is required.