P roblem S olving I nnovator Solving Tomorrows Problems Today IS - IS NOT / COMPARITIVE ANALYSIS...
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Transcript of P roblem S olving I nnovator Solving Tomorrows Problems Today IS - IS NOT / COMPARITIVE ANALYSIS...
Problem Solving I nnovatorSolving Tomorrows Problems Today
IS - IS NOT / COMPARITIVE ANALYSIS motivates deliberate thinking about the Boundaries of What Is or Is Not.
WHATObject / Deviation
WHERESeen on Product / Process
WHENFirst seen / Last Reported
HOW BIGHow many objects / Defects
COVER PAGE
D2 – Fill in the data for the ‘WHAT’ section accordingly
WHAT section
HelpWhat object has the Defect?Auto Input from Problem Workbook
HelpWhat similar object(s) could have the Defect
HelpCONSIDER Part NumbersShop Floor DescriptionsCustomer Descriptions
HelpWhat is the Defect?Auto Input from Problem Workbook
HelpWhat other Defects “could” have been observed?
HelpWhat has changed In / and / aroundthis difference?
HelpDate change was reversed. If still same ? Enter “current”
HelpHow could these Differences or Changes have Created or Causedthe Problem – as it is defined?
Other Similar Valves
Major Leak
Data to confirm Problem has not previously occurred on similar Parts
HelpWhat could CAUSE the Difference between the IS Compared to the IS NOT?
Different Operating Conditions
Higher Operating Pressure
Seal introduced to cope with increased pressure
HelpCONSIDER How could the “changes” Have CAUSED the “differences”
Used only by TooGood Motor Corporation
Current
D2 – Fill in the data for the ‘WHERE’ section accordingly
WHERE section
HelpWhere specifically on the object does the Defect occur?
HelpWhere in the Process Flow is the Defect seen
HelpWhere specifically on the object does the Defect occur?
HelpWhere could the Defect have been observed?
HelpCONSIDEREnvironmental factorsContaminationPossible Abuse
HelpWhat could CAUSE the Difference between the IS compared to the IS NOT?
HelpCONSIDERHow could the “changes” have CAUSED the “differences”
HelpWhat has changed In / and / aroundthis difference?
HelpHow could these Differences or Changes have Created or Caused the Problem – as it is defined?
At other Joints
On the Pressure Test
Validate Leakage in Field
Vibration of Valve
Loss of Torque on Union
Used in Potentially harsh Operating Conditions
Vibration could weaken Torque on Union
Around Sealing Washer
When Vehicle is in the Field
D2 – Fill in the data for the ‘WHEN’ section accordingly
WHEN section
HelpWhat has changed In / and / aroundthis difference?
09-Feb-11
02-April-12
After three months of use
Before 27-Mar-12
During Product/Vehicle Testing
Validate Service History
Product Cycle Time Loss of Torque
Seal Surface deteriorates
Valve was subject to Operating Conditions and Seal possibly “settled in”
Vibration could weaken Torque on Union
HelpWhen in time was the Defect first observed?
HelpWhen was it Seen But NOT Reported
HelpWhen in time “could the Defect have been observed?
HelpWhere “should” the Defect have been seen, but wasn’t.
HelpCONSIDERMode of OperationModifications/ChangesReliability Data
HelpWhat could CAUSE the Difference between the IS compared to the IS NOT?
HelpCONSIDERHow could the “changes” have CAUSED the “differences”
HelpHow could these Differences or Changes have Created or Caused the Problem – as it is defined?
HelpWhen since that time has it been seen?
HelpConsider changes in the Process Cycle.
HOW BIG section
D2 – Fill in the data for the ‘HOW BIG’ section accordingly
HelpWhat has changed In / and / aroundthis difference?
HelpHow many units, items, objects, have the defect? Use % or how many out of?
HelpIs the Problem getting Bigger/ Stable / Smaller?
HelpHow often “could” the Defect occur
HelpCould the Problem be worse or better without intervention?
HelpCONSIDERWarranty ReturnsQuality RecordsCP / Cpk
HelpWhat could CAUSE the Difference between the IS compared to the IS NOT?
HelpHow could these Differences or Changes have Created or Caused the Problem – as it is defined?
HelpHow many Defects per Object, Part or Unit?
HelpCONSIDERHow could the “changes” have CAUSED the “differences”
One
8 from 40,000 units
Erratic
On 39,992 units
Multiple Leaks
Predictable
Investigate “unreported” instances from routine Servicing
Interpretation of extent of Leakage
Operational Use
Different Service Outlets Different Service Outlets
HelpHow many objects “could” have had the Defect?
Problem Solving I nnovatorSolving Tomorrows Problems Today
This completes theD2 Comparative Analysis
Now start the Flow Chart