Problem Discovery
Department: Name:
Problem Discovery
Collect the Facts about the Symptoms (Get facts) |
Behind schedule by… | Productivity is… |
Rework is… | Work habits are… |
Scrap is… | Job interest is… |
Machine downtime is… | Complaints are… |
Accident rate… | Attendance is… |
Setup time is… | Job satisfaction is… |
Explore Possible Causes for Critical Symptoms |
| |
| - Faulty instruction and follow up
|
| - Insufficient skill and experience
|
| |
| |
- Working conditions or housekeeping
| - Health and physical fitness
|
| |
Barriers to Solving Problems |
|
|
|
|
|
Problem Discovery
People Problems | Method Problems |
Don’t know - Can’t Do | Don’t care, Won’t do | Process, Layout, Materials, Tools, Equipment, Design |
Improve: Knowledge, productivity, skill | Improve: Attitude and behavior | Improve: Method for a better way |
Production Problems | Personnel Problems |
- Deliveries delayed because of errors and mistakes of people making the parts.
- Employees don’t know their jobs.
- Mix-ups in trucking service.
- Parts returned by another department because they were not made right.
- Operators have special problems because of engineering changes.
- Poor planning.
- Employees have difficulty in getting up to production on new type equipment.
- Aisles too congested.
- Excessive wear and tear on equipment
| - Employees leave to other plants – couldn’t “get the hang” of the job.
- New employees lack experience in mechanical things.
- Lack interest in the work.
- Employees want transfers - think they can “make out” better on other jobs.
- Claim to have good experience but don’t “come through.”
- Too much time to get up to production.
- Instructed the wrong way.
- Can’t get experienced people any more.
- Employees get discouraged learning the job.
|
Safety Problems | Quality Problems |
- Safety equipment not properly used.
- Material not piled properly.
- Poor shop housekeeping.
- Don’t know safety rules.
- Employees don’t know hazards of their jobs.
- Employees get careless.
- Minor injuries not reported.
| - Not meeting inspection standards.
- Too much scrap or re-work.
- Jigs and gauges not properly used.
- Not following specifications.
- Too much left to operator’s judgment.
|
Plus/Minus exercise – list operators with job skills that are the best in the team and weakest.