Unit Three: Analyze Causes of a Problem PDF

Unit Three: Analyze causes of a problem 3.1. Possible causes of a problem Waste of defects can be caused by ▪Inefficiencies in manufacturing processes ▪Unclear operating procedures and ▪Poor quality raw materials from suppliers or ▪Staff who are poorly trained in the use of machinery or to...

Unit Three: Analyze causes of a problem 3.1. Possible causes of a problem Waste of defects can be caused by ▪Inefficiencies in manufacturing processes ▪Unclear operating procedures and ▪Poor quality raw materials from suppliers or ▪Staff who are poorly trained in the use of machinery or tools. Common causes of Inventory Waste include: ▪ Overproduction of goods ▪ Delays in production or 'waste of waiting’ ▪ Inventory defects ▪ Excessive transportation 3.2. Cause relationships using 4M1E 3.2. Cause relationships using 4M1E ▪ The 4M is a method that allows to identify and group causes that impact to a specific effect. 4M categories (Material, Method, Machine, and Man). Showing 4M1E Cause and Effect Diagram with 4M1E 3.3. The root cause of the problem Definition of root cause ▪ Root causes are the basic reasons behind the problem or issue you are seeing in the community. What is the "but why?" technique? ▪ The "But why?" technique is one method used to identify underlying causes of a community issue. These underlying factors are called "root causes." ▪ The "But why?" technique examines a problem by asking questions to find out what caused it.Each time an answer is given, a follow-up "But why?" is asked. Why should you identify root causes? ▪ Identifying genuine solutions to a problem means knowing what the real causes of the problem are. ▪ Taking action without identifying what factors contribute to the problem can result in misdirected efforts, and that wastes time and resources. ▪ The "But why?" technique can be used to discover basic or "root" causes either in individuals or broader social systems: When should you identify root causes? ▪ Whenever you are faced with addressing a challenging community problem. Of course, the "But why?" technique is not always your best bet and should not be used 100% of the time. ▪ For some issues, however, you should use more sophisticated methods, such as surveys, interviews and data collecting. ▪ How does the "but why" technique work? Here's how it works. A group examines a community problem by asking what caused it. Each time someone gives an answer, the "asker" continues to probe, mostly by asking "But why?" 3.4. Creative idea generation to eliminate most critical root causes Definition of idea generation ▪ The process of actively creating, developing, and communicating new ideas, often involving brainstorming and creative thinking to come up with potential solutions to problems; whether individually or within a group ▪ To put it simply, it‘s the process that requires finding new solutions for practical problems in all fields of life and work. 3.4.2. Elements of creative idea generation All you need are the four essential elements of Creativity. ▪ Focus- Find an area of general or specific focus ▪ People- The number of people only depends on who is around --- you can do it with. ▪ Tools- Thinking tools are essential --- you can use simple tools such as SCAMPER. ▪ Time 3.4.3. Idea generation methods The 5W+H Method ▪ The technique represents basic questions you need to ask when thinking about a specific topic: Who, what, where, when, why, and how? Social Listening ▪ Idea generation doesn‘t mean you have to come up with a great suggestion single-handedly. ▪ sometimes it‘s enough to do a little bit of social listening and see what the target audience has to say about a certain topic. Brainstorming Brainstorming is a well-known method that people all over the world use for decades already. What makes this tactic so popular? Well, it‘s the fact that no one gets laughed at for proposing a There is no right or wrong here – you just need to say the first thing that comes to your mind and that‘s it. Role Playing ▪ The only way to break the barrier and think of a brilliant idea. The process is simple: you just need to switch places with your colleagues and try to embrace their point of view. It doesn‘t guarantee immediate results, but it often leads to interesting conclusions and brand new ideas. Use Online Tools The Internet is filled with interesting tools that can assist you in identifying alternative ideas. You can choose between many different options, but the final decision usually depends on the nature and peculiarities of your business. Mind Mapping ▪ a mind map is a diagram for representing tasks, words, concepts, or items linked to and arranged around a central concept or subject using a non-linear graphical layout that allows the user to build an intuitive framework around a central concept. Thinking Reverse ▪ The last solution on our list is very amasing. Instead of thinking about how to reach your goal, you can think about how not to achieve it. 3.5. Summaries of the Action Plan Concepts of Action Plan ▪ Actionplanning is the process in which you plan what will happen in the project or organization in a given period of time. ▪ In project management, an action plan is a document that lists the action steps needed to achieve project goals and objectives. ▪ Action plan clarifies what resources you‘ll need to reach those goals ▪ Determines what team members you‘ll need to do it all. 3.5.2. Writing an Action Plan When someone prepare an action plan for Muda identification, the following things have to be considered: A. Define your Goals ▪ Project goals refer to the high `level goals that the project will achieve. Those generally align with the strategic planning and business objectives of organizations. B. Define your Objectives ▪ Project objectives refer to the deliverables and milestones that need to be completed to achieve your project goals. C. Define Action Steps The action steps are a group of related tasks or action items that must be executed to produce project deliverables. D. Identify and Prioritize Action Items Action items are small, individual tasks that make up the action steps that are outlined in your action plan. E. Define Roles & Responsibilities Now that you‘ve divided the work required to accomplish your action plan, you‘ll need to assign action items to your project team members and define their roles and responsibilities. G. Set SMART Goals Your action plan needs to be monitored and controlled to measure its performance. SMART goals stand for specific, measurable, attainable, relevant and timely. Specific: Well defined, clear, and unambiguous Measurable: With specific criteria that measure your progress toward the accomplishment of the goal Achievable: possible to achieve Realistic: Within reach, realistic, and relevant to your life purpose Timely: With a clearly defined timeline, including a starting date and a target date. SELF CHECK QUASTIONS Unit Four: Eliminate MUDA and Assess effectiveness of the solution 4.1. Plan of MUDA elimination by medium KPT(KaizenPromotionTeam) members 4.1.1. Muda elimination ▪ Muda translates roughly as waste, and refers to the inefficiencies within processes which you can seek to reduce or eliminate entirely. ▪ Muda is anything that does not have value or does not add value. ▪ Waste is something the customer will not pay for. 4.1.2. Ways to reduce waste A. Identify the Key Areas of Waste B. Manage Inventory Efficiently -Efficient inventory management means keeping the proper inventory (including raw materials, WIP, and finished goods). -The goods you will produce follow your customer demands. -You need to make sure that the amounts and types of materials you keep are adequate for your production. C. Reduce Packaging Materials Usage ▪ Product packaging is one of the significant contributors to waste. ▪ Good packaging designs are sometimes needed to highlight the uniqueness of your product. ▪ Redesign your product if that‘s possible. ▪ For example, replace your product packaging with reusable and recyclable materials for starting a zero- waste lifestyle. D. Establish Routine Maintenance Schedules ▪ Check the condition of your machines and equipment regularly. ▪ You will end up spending more on new machines and equipment. Therefore, it‘s important to schedule regular preventive maintenance. ▪ HashMicro‘s Manufacturing System can make it easy for you to record conditions and schedule routine maintenance for all manufacturing assets. ▪ The system also allows you to monitor fuel consumption and track your truck‘s location to identify problems early. E. Use Automation for Your Business ▪ You may be thinking that investing in software is not the right solution to reduce waste since you will still need to spend quite a lot of money to implement it. ▪ The cost you will spend on software is much cheaper than the costs you have to pay regularly on your workers, new machines, reparations, and other unnecessary tools. 4.2. Tools and techniques to eliminate wastes/MUDA 4.2.1 Adopting the Necessary Attitude ▪ First you must adopt an attitude that supports your ability to see waste. ▪ It is very important that you understand that one purpose of discovering waste is to take the frustration out of your work. 4.2.2. The Ten Basic Principles for Improvement 1. Throw out all of your fixed ideas about how to do things. 2. Think of how the new method will work-not how it will not. 3. Don‘t accept excuses. Totally deny the status quo. 4. Don‘t seek perfection. A 50 percent implementation rate is fine as long as it is done on the spot. …Cont’d 5. Correct mistakes the moment they are found. 6. Don‘t spend a lot of money on improvements. 7. Problems give you a chance to use your brain. 8. Ask ―Why?‖ at least five times until you find the ultimate cause. 9. Ten people‘s ideas are better than one person‘. 10. Improvement knows no limit. 4.2.3. Elimination of the seven types of Wastes/Muda A. Eliminating Overproduction Wastes In order to balance capacity and load without overproducing, you must implement the advanced methods of lean production: ▪ Full work ▪ Line balancing(the assignment of the right number of workers and machines to each assembly line segment) ▪ Pull production using kanban(uses visual signals to indicate when to produce or move items in a production process) ▪ Quick-changeover operations. ▪ Level production - production rate over a set period of time. B. Eliminating Inventory Wastes U-shaped manufacturing cells, layout of equipment by process instead of operation. ▪Production leveling ▪Regulating the flow of production ▪Pull production using kanban ▪Quick changeover operations C. Eliminating Motion Wastes ▪ Gradually switch to flow production ▪ Create U-shaped cell layout of equipment ▪ Make standardization through ▪ Increase training ▪ Increase operator awareness about motion during an operation D. Eliminating Conveyance/Transportation Wastes ▪U-shaped manufacturing cells ▪Flow production ▪Multi skill workers ▪Standing to perform operations ▪Higher utilization rate ▪Water beetles (material handlers in the kanban system of pull production) E. Eliminating Waiting/Idle Time Wastes ▪ Production leveling ▪ Product-specific layout ▪ Mistake-proofing( prevent or detect errors in a process) ▪ Human automation ▪ Quick changeover ▪ Autonomous maintenance ▪ Line balancing G. Eliminating Processing Wastes ▪ More appropriate process design ▪ Review of operations ▪ Improvement of jigs using automation ▪ Thorough standardization ▪ Promotion of value analysis(VA) and value engineering(VE) techniques( a methodology for optimizing product value) 4.3. Report improvements 4.3.1. Definition of reporting ▪ Reporting means relating to the issuing of reports. ▪ A reporting entity is an organization or company, or group of companies that prepares financial reports. 4.3.2. Purpose of reporting ▪ Reports communicate information which has been compiled as a result of research and analysis of data and of issues. ▪ Reports can cover a wide range of topics, but usually focus on transmitting information with a clear purpose, to a specific audience. Types of report There are different types of reports. Among those the following are listed below. ▪ Formal or Informal Reports examples of formal report: Formal reports include research reports, proposals, feasibility studies, business plans, compliance reports, and periodic reports. Examples of informal reports: Memos, emails, and papers ▪ Short or Long Reports ▪ Informational or Analytical Reports ▪ Proposal Report ▪ Vertical or Lateral Reports ▪ Internal or External Reports Internal Reports used by employees and management to make decisions, assess performance, and plan for the future. External reports-are shared with stakeholders outside of the organization, such as shareholders, regulatory agencies, potential investors, lenders, and creditors. ▪ Periodic Reports Good report ▪ Structure in a logical and coherent order; ▪ present your report in a consistent manner according to the instructions of the report brief; ▪ make appropriate conclusions that are supported by the evidence and analysis of the report; ▪ make thoughtful and practical recommendations where required. Characteristics of Good or Essential report ▪ Suitable Title ▪ Simple ▪ Promptness ▪ Comparability ▪ Consistency. ▪ Precise and Accurate ▪ Relevant Information ▪ Presented to Required Person or Group or Department Directions: Answer all the questions listed below. Part I: Say True or False 1. Muda is anything that does not have value or does not add value. 2. A reporting entity is an organization or company, or group of companies that prepares financial reports. 3. Periodic report is one of the types of report. Part II: Choose 1. Of the following which one is the way to reduce wastes? A.manage inventory efficiency B. reduce packaging material usage C. leverage automation D. all E. none 2. Which one isnot Characteristics of Good or Essential Report? A.Suitable Title C.Promptness E. none B. Simple D. all 3. How can you Eliminating Inventory Wastes? A.byProduction leveling B.By Pull production using kanban C. By regulating the flow of production D. By quick changeover operations E. all Part III: Short Answer 1. List down the type of report? (4 points) 2. Write at least two methods how to eliminate each of the seven deadly wastes. (5 points) 3. What are the characteristics of essential report? (5 points)