|
Home Industrial Forum Home 
|
Manufacturing Process Improvement: Eliminating waste in defectsAll listings are the responsiblity of the posters; keep in mind, anyone can post anything! |
 us |
|
| ||
|
Home Industrial Forum Home
|
Manufacturing Process Improvement: Eliminating waste in defectsAll listings are the responsiblity of the posters; keep in mind, anyone can post anything! |
us |
|
| ||
IndustrialManufacturing Process Improvement: Eliminating waste in defects
An obvious type of waste is work that has defects. For anything that doesn’t meet the required specifications, either you need to throw it away (losing the money spent on materials and parts, along with the time spent to produce it) or do more work to make it acceptable.
How to identify the root cause of defects Many times when a problem happens, people don’t investigate the root cause. All they look for is the immediate cause of the symptom, and try to find a way to mask that. Unfortunately, that rarely eliminates the real problem. Lean manufacturing uses the “five whys” to get to the root cause of the problem, and prevent it from happening again. For instance, if someone drops a part because they slipped in some oil on the floor, a typical response would be, “Watch where you’re walking.” That isn’t the most useful plan to prevent the problem from happening again later. Using the five whys, you would ask:
Now you’ve gotten to a point where you can come up with a way to prevent the problem from happening again – regularly schedule preventative maintenance of your equipment. Even though this practice is named the “five whys”, it doesn’t mean that you will always need to “why” five times. Sometimes you get to the root problem quicker, sometimes it takes longer. The purpose of this practice is to ask as many times as it takes you to get to the root problem, and come up with a real solution. You don’t want to look for a reason why something went wrong. Instead, you want to look deeper for the reason why the process failed, so you can make a change to your process. It’s also important to note that this technique is not meant to be used to blame a person. If someone did something wrong, then you need to change your process to include training for that person, or, even better, change your process so that step can never be performed incorrectly. For example, let’s say you have two electrical components you need to connect. There are two lead (a positive and a negative) that need to fit into a socket. If the leads are accidentally reversed, there will be an electrical short and the parts will be damaged. If both leads are the same size and shape, you may end up with an operator accidentally reversing them, and damaging the parts. However, if you design the parts so the positive lead and the positive socket are square, while the negative lead and socket are round, then they can never be connected incorrectly. You’ve permanently eliminated the problem. Summary When you see a defect, don’t just look for a way to correct the immediate symptom. Look for the root cause, and find a way to prevent the problem from ever happening again. Keep doing this and you’ll see your cost of rework dropping, and your quality rising. You can talk about... Manufacturing Process Improvement: Eliminating waste in defects Tags: • preventative maintenance • root cause • technique • maintenance • machine • materials • specifications • waste • manufacturing • electrical components • lean manufacturing • how to • process improvement • manufacturing process • Related articles:
Manufacturing Process Improvement: Eliminating waste in defects Industrial |
Have you added a link to us from your website? (2728686687):
(rozwqizwipzerr) Privacy & DMCA Policy -- Sitemap |
