Beruflich Dokumente
Kultur Dokumente
Problem Solving
Carol Kurtz
CJ Kurtz & Associates LLC
Quality Engineer
Certified Quality Auditor
Certified Quality Manager
Certified Mechanical Inspector
Course Objectives
Understand
Corrective Action
Action
Problem Solving
Problem
What is 8D?
8D
Why 8D?
8D
Tests
Documented
8D Corrective Action
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Some Vocabulary
Problem
Effect
Symptom
Cause
Concern
Special
Root
Problem
Failure Mode
Cause
Common Cause
Root Cause
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Structure of a Problem
Determining
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Structure of a Problem
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Structure of a Problem
(continued)
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Structure of a Problem
(continued)
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Classifying Problems
Correctly
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Floor Problems
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Problems
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Process Improvement
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Trend Chart
Control Chart
Pareto Chart
Brainstorm
Checksheet
Histogram
Nominal Group
Technique
Five Whys
Computer Aided
Engineering
APQP
Situation Analysis
Flowchart
Failure Analysis
Database
Decision Analysis
Action Plan
Root Cause Analysis
Cause & Effect Diagram
Scatter Diagram
Design of Experiments
Poka Yoke
Preventive Action Matrix
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Purpose
8D Step
Indicator to track magnitude of D1 D2 D3 D4 D5 D6
symptoms
D7 D8
Pareto Chart
D2 D8
Paynter Chart
D2 D3 D6 D8
Repeated Why
D2 D4 D5 D6
D1 D2 D3 D4 D5 D6
D7 D8
D1 D2 D3 D4 D5 D6
D7 D8
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RACRoot Cause
Analysis
Problem
Solving
Tools
?
RACRoot Cause
Analysis
Pareto
Analysis
?
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the problem!
Nonconforming
Product
Out of Control Conditions on Charts
Rework
Trend Charts
What others?
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Or Here?
Supplier
In
Tran
sit
Or Here?
Or Here?
In-Process
Inventory /
Shipping
Company
Receiving /
Inventory
Or Here?
Or Here?
Or Here?
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In
Tran
sit
Or Here?
Customer
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Product
Out of Control Conditions on Charts
Rework
Trend Charts
What others?
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Average
Trends
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A Run of 7 successive points above or below the center line is an out of control condition.
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Sudden, Unpredictable
Instability
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Stratification
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1. CHECK
Check that all calculations and plots have been accurately completed,
including those for control limits and means. When using variable charts,
check that the pair (x bar, and R bar) are consistent. When satisfied that
the data is accurate, act immediately.
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Functional or Multi-Disciplinary
Process Owner
Technical Expert
Others involved in the containment,
analysis, correction and prevention of
the problem
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Several roles need to be established for the team. These roles are: Leader,
Champion, Record Keeper (Recorder), Participants and (if needed)
Facilitator.
Leader
Group member who ensures the group performs its duties and
responsibilities. Spokesperson, calls meetings, establishes meeting
time/duration and sets/directs agenda. Day-to-day authority, responsible for
overall coordination and assists the team in setting goals and objectives.
Participants
Record Keeper
Writes and publishes minutes.
Champion
Guide, direct, motivate, train,
coach, advocate to upper
management.
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define goals
Clearly defined responsibilities
Trust & Respect
Authority
Positive Atmosphere
Good two way communication
Effective action plan with timing
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statement =
Object + concern + quantification
Example:
Remember:
half solved!
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Frequency
Percent
(%)
Cum Percent
(%)
Bonder Set-up
Issues
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38%
38%
Unetched Glass
on Bond
Pad
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22%
60%
Foreign Contam
on Bond
Pad
18%
78%
Excessive Probe
Damage
6%
84%
Silicon Dust on
Bond Pad
4%
88%
Corrosion
2%
90%
2%
92%
Cratering
2%
94%
Resin Bleed-out
2%
96%
Others
4%
100%
Total
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100%
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12-16-04
Defect
1st Shift
2nd Shift
3rd Shift
Totals
Nicks
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14
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Missing holes
Missing screws
12
Totals
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18
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D3: Containment
Define
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D3: Containment
Contain Symptom Flow
Immediate Containment
with Current
Information and
Problem Description
Determine
Escape Point
Choose
Verify Before
Implement
Certify parts and Confirm
Customer Dissatisfaction
No Longer Exists
Should an existing check (control)
have caught the defect?
Validate After Implementation
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D3: Containment
Objectives
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D3: Containment
Containment Action Checksheet
Containment Action Checksheet
Yes
No
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Root
Cause of Escape
What system allowed for the event to escape
without detection?
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Is Not
What:
Object
Heavy traffic
Defect
Late Employees
Where:
Seen on object
I-70 Expressway
Seen geographically
When:
First seen
July 7, 1996
Ever since
Afternoon
How Big:
How many objects have the defect?
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Strongly correlated
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Moderately correlated
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No Correlation
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Orientation
Poka Yoke
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1
6
Spring loaded
shutter
mechanism - Do
you remember
the old 5.25 inch
floppies from the
early to mid1980s? Failsafe
disk surface
protection [#4].
Slide Tab to
protect against
erasure.
Mechanism
senses [#5].
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Computer Floppy
Drives
Microsoft: Disk must
be inserted and ejected
by hand. It is possible
to eject a disk while it is
being written to.
Macintosh Poka Yoke
(1984): Disk drive grabs
disk as it is being
inserted and draws it in
and seats it. Disk
cannot be manually
ejected. You must drag
the desktop icon for
the disk to the Trash.
The drive then ejects
the disk as long as
there are no disk
operations taking place.
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Yes
No
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References
http://elsmar.com/
http://www.isixsigma.com/spotlight/default.asp
http://www.isixsigma.com/dictionary/glossary.asp
http://www.asq.org/learn-about-quality/
Prince Corp, Corrective Action Manual
The New Rational Manager, Kepner & Tregoe
http://deming.eng.clemson.edu/pub/tutorials/
http://www.qualityspctools.com/menu.html
Ford Team Oriented Problem Solving
http://www.cjkurtz.com/qualitytools.htm
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