Problem Solving 5 Why[1]

8/3/2019 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




2

Supplier Development Eskilstuna 3rd February

Is there a clear joint plan toachieve the project targets ?




3

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.

o----------------o---------o

o---------------o--------oo------ o-------o

o------o----o

o---o----o

o----o-----o

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




4

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.





5

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


Clear understanding of problem cause

and countermeasure required




6

K now How Collection

± 8D Approach Example

Case Study 40 mins

Supplier Development Eskilstuna 2nd February






7

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




8

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




9

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




10

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




11

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 ?




12

K now How Collection

± 5why Approach Format & Purpose

Example

Case Study 40 mins







13

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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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.




15


Shortcut to 5 why BLANK.lnk


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




16

5 Why Example.

R oot cause can not be established withcurrent data !!


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.

Problem Solving 5 Why[1]

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