Jigs and Tools General Tools, Cutting Tools,

Jigs, Molds, Dies, Frames,

Fixers, Pulley Blocks, Jacks, etc
Spare Parts Standby Equipment, Spares,
Permanent, Stocks, Auxiliary
Materials, Obsolete or Surplus
Makeshift Repairs Tape, String, Wire, Metal Plates,
Scaffoldings, Sealant, Clamps
Electrical
Equipments
Wiring Piping, Power Leads,
Switches, Plugs, Sockets, Fuses,
Stamping
Unnecessary Items
Unevenness, Ramps, Cracking,
Peeling, Wear (Steel Deck plates),
Oil Spills
Floors
Steps Too Steep, Irregular, Peeling of
Anti-slip Covering, Corrosion,
Missing Handrails
Lights Dim, Out of Position, Dirty or
Broken Covers, Not properly
explosion proofed
Unsafe Areas
Rotating Machinery Displaced, Fallen off or Broken
Covers, No Safety or Emergency
Stop Devices
Lifting Gear Wires, Hooks Brakes and other
parts of Cranes and Hoists,
Absence of Fencing
Others Special substances, Solvents,
Emission of Toxic Gases,
Insulating Materials, Danger
Signs, Protective clothing,
Unguarded Pits, Platforms,
Weld spark, High Voltage,
Explosive Storage, Loose Wires
Unsafe Areas
Unsafe Practices
Human
Non adherence to safety standards,
e.g. use of helmets, gloves, goggles;
Improper use of Tools, Unconscious
and overconfident
Safety
Equipment
Inadequate / Improper Safety
Equipment, Dislocation of the
Equipment, Poor condition of the
Safety equipment, Expired, Poor
House Keeping
Inadequate
Information
No Visual Displays / Caution Boards,
Inadequate Training / Lack of
awareness
Operating
Environment
Improper humidity, temperature,
light, etc.
ABNORMALITIES IDENTIFIED
MINOR FLAWS - 09
UNFULFILLED BASIC CONDITIONS - 11
INACCESSIBLE PLACES - 05
CONTAMINATION SOURCES - 07
QUALITY DEFECT SOURCES - 01
UNNECESSARY & NON URGENT ITEMS - 07
UNSAFE PLACES - 31
TOTAL
71
WCM - TEAM NO. 6 UNIT - III
RAW MILL HOPPER TOP AREA
CABLE TO BE
GLANDED
GREASE
NIPPLE
MISSING
IMPROPER
DESIGN AND
FITTING OF
GUARDS
DISCCHARGE OF. 3
BC-5
SLIGHT OIL LEAKAGE
FROM G.B
GE
AR
BO
X
MOT
OR
AIR LINE
DAMAGED
BAG
FILTER
3BC-5 DRIVE STN.
Know Your Equipment and
Processes
Abnormality
Description
Root Cause
(Why-Why Analysis
Action for
Removal
Responsi-
bility
Date
Area: Sub Station -1 Type of Abnormality: Unfulfilled basic condition
1
Rusted cable tray
& undressed
cable.
2
3
MEMBERS: M/S MA SHEIKH, KN JAJOO, S NARANG,A SIGHAL, AK PANDEY,
TEAM NO. - 4 LEADER: AC SHARMA Page 1
Lack of
supervision
Cable tray to
be painted &
cables to be
dressed
.Oil leakage from
Transformer
Switch board at
rear of MCC-4 is
loose on mounting
Electrical 31.8.98
Due to decay of
wooden bead
To be repaired
Electrical 31.8.98
Mishandling
in Installation
To be repaired
Civil 15.8.98
Abnormality Identification and
Removal Plan
TYPE VISIBLE SYMPTOMS SUGGESTED COUNTER
MEASURES
Inventory Too much fuses, lugs and
connectors are kept in
almirah
Stock of spares shall be
studied and surplus spares
shall be returned to stores
Surplus MLDB panel is
kept in Sub station idle
The panel shall be shifted
to stores
Defects Light in PAB A converter
room is insufficient
Tube lights shall be
replaced with new one
Waste Identification Format
Second Step: Sharpen the Mind
for understanding the Root Cause
Employ tools such as Why-Why Analysis and
Cause and Effect Analysis. (see Problem
Solving section)

Remember:
Understand the Physical Phenomenon and
Operating Principles
Understand the correlation of Man, Machine,
Method and Materials (4M)
Procure Ideal Values
Tools and Techniques for
Problem Solving
Innovations
Step 2 - Equip the Teams with:
Training shall emphasize on transfer of knowledge
in respect of the tools and techniques, viz.:
Visual Management and Control
5 Why Analysis
Cause & Effect Analysis (Ishikawa Diagram)
Failure Mode and Effect Analysis (FMEA)
PM Analysis
Plan Do Check Act (PDCA)\Deming Wheel
Value Analysis\ Management
COQ and PONC
Benchmarking\Best Practices
Business Process\ Management Reengineering
Idea Generations: Brainstorming & Mind-
Mapping
SMED/QCO
Cause and Effect through Cards: CEDAC, etc.
Weapons, Tools and Techniques
Water Dripping in Substation 1
WHY ?
WHY ?
WHY ?
WHY ?
Water accumulated at the roof
Outlet drain chocked
Atmospheric dust & dirt
Periodic cleaning of drain not done
Action
Proper scheduled procedure for roof cleaning is to be prepared
Steps For P-M Analysis
1) Clarify the phenomenon
/ problem
Classify the phenomenon thoroughly
2) Conduct physical
analysis of the
phenomenon
Analyse the problem from the physical point of
view and present them by referring to the
principle and rules
3) List factors related to
the phenomenon
Pin point all the conditions that consistently give
rise to the problem
4) Study the relation
between equipment,
man, materials and
methods
Investigate the correlation between equipment
and tools under which failure conditions are
generated and list up the factors which might
have a cause and effect relationship
5) Study what the normal
conditions are
Study the optimal conditions for each factor
related to mechanisms, actual equipment drawing
and various other standards
6) Plan the appropriate
investigation methods
Survey the methods which are useful for
investigating the factors
7) Identify malfunctions List up the items which are deviating from the
normal conditions and items of incidental defects
8) Implement an
improvement plan
Draw up and implement the improvement for the
malfunction points and controlling its recurrence
Phenomena
Physically View
(Logical reasoning)
Contributing condition

The frictional heat on
striking is not
sufficient enough to
catch up to the fire
point


1. Defective surfaces -
chemical
composition is not
proper
2. Presence of
moisture
3. Striking force is
very low



A match doesnt
strike at once


Physical Phenomenon Mechanism
(PM) Analysis
Work Environment, savings through 5S
Waste Elimination
JIT; savings through reduced investments in
stocks, material handling/ losses, Kanban
Autonomous/ Self Maintenance, benefits
through Prevention Culture
Planned Maintenance, savings through RCM,
breakdown reductions, etc.
Third Step: Conduct Workshops
and demonstrate benefits
SPC/ SQC
Cost Management, including Supply Chain
related costs, COQ,
PM Analysis, for Chronic Problems relating to
breakdowns, Quality, etc
Value Engineering
SMED/ QCO
FMEA
OEE improvement workshop, savings through
machine breakdowns, improved availability,
corrections in output rates and equipment
related Quality issues


Third Step: Conduct Workshops
and demonstrate benefits
Third Step: Conduct Workshops
and demonstrate benefits
FMEA
MP Design
MOST for work measurement, ABC Analysis,
Productivity improvement
World Class Office Management; savings
through de-bottlenecking
Kaizens
Poka Yoke, savings through defect prevent
Organization and Method Studies
Visual Management & Control
Measure and Monitor Visually,
QCDIP
Process Performance
Eight Dimensions Status
Like Olympics, Teams compete with each other
and the results are visually seen by all the
employees. Achievements and successes are
recognized/ celebrated
Poka Yoke (Zero Quality Control) principles are
followed


Visual Controls for Abnormalities to show
themselves, early and quickly

Team Score Cards for Measuring and
Monitoring . Team Competition Boards

Achievers Contest within the Group

Competition amongst Teams and Plants, akin to
Olympic Games

Process Step 3: Visual Competition