tcb_roadmap_to__qualitiy_vol1

The methods to be used to confirm that abnormalities

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Unformatted text preview: need them to prepare your action plan afterwards. Where appropriate ask yourself the RADAR questions. Note: Always include in your discussion any figures referred to in the text, if you feel these are relevant to your company. a. Parag. 1: Do you agree that these are the first actions that should be taken? Give an example from your own experience to justify your opinion. b. Parag. 2: Give examples from your own experience where emergency action was taken for each of these reasons. What might have happened in these examples if emergency action had not been taken quickly? c. Parag. 3 presents guidelines for preventing abnormalities escalating. Apply the RADAR questions to these. What improvements would you expect from the application of such guidelines? Unit 9 - Problem solving 12 A Roadmap to Quality 05-87581_unit 9.qxd 09/09/2005 11:49 Page 13 d. Parag. 4 specifies three procedures that need to be clearly defined. Apply the RADAR questions to these. e. Parag. 5 presents the ISO 9001 guidelines for constructing a management system for non-conforming products. Apply the RADAR questions to these guidelines. Be as concrete as you can in your discussion. Action plan Take the ideas you have found useful in the text, and in your discussion, and present them in a well-structured action plan for introducing improvements in your company. You might like to follow the 6-Point Structure. Alternatively you may choose to prepare one action plan when you have discussed several texts. A Roadmap to Quality 13 Unit 9 - Problem solving 05-87581_unit 9.qxd 09/09/2005 11:49 Page 14 9.4 Preventing the recurrence of abnormalities Introduction 1. Pay special attention to any causes of abnormalities that are related to work processes and job procedures, and try to get to the root causes. Once the root causes are known, take recurrence prevention measures to prevent these causes bringing any more problems. The combination of emergency action, when it is necessary, and systematic recurrence prevention measures, will provide stable production. Get to the root causes 2. Causes can vary from one abnormality to the next. However, in many cases, it is only the first, immediate causes that differ. An examination of secondary and third level causes of different abnormalities often leads investigators to the same source cause. If you do not investigate right to the source cause, the problems can recur. It is often useless to deal only with the various first causes each time an abnormality emerges. This is not dealing with the real problem but only with the results of the problem – the phenomena. 3. Look at the example in Figure 9.4a below: Phenomena and their causes Countermeasures Machines came to a halt. Why? Because: Fuses blew due to an overload. Why? Replace fuses. Because: Bearing lubrication was insufficient. Why? Increase the rotation frequency of the lubricating pumps. Because: Lubricating pumps were in poor condition. Why? Replace pumps. Because: Pump axis were worn out. Why? Replace axis. Because: Sludge had entered. Attach filters to lubricating pumps. Take recurrence prevention measures 4. When the fundamental causes have been identified, proper recurrence prevention measures can be taken. One definition of recurrence is the re-emergence of abnormalities due to the same causes within three years (or of the same abnormalities if the causes have not yet been found). Managers should always consider whether an abnormality is a new one or a recurring one. If it is a recurring one, then any causes previously identified were probably not the fundamental causes. Unit 9 - Problem solving 14 A Roadmap to Quality 05-87581_unit 9.qxd 09/09/2005 11:49 Page 15 5. Recurrence prevention measures can be taken in three stages: a. Stage 1. Measures aimed at the operations in which the problems are identified. b. Stage 2. Measures aimed at similar operations. c. Stage 3. Measures aimed at the overall system. 6. Example: a. Stage 1: After materials have been put wrongly in storage, improve the storage facility and the written input directions. b. Stage 2: Review the storage locations and write input directions for other materials. c. Stage 3: Improve the criteria for setting up storage locations and the procedure for preparing written input directions. Similar abnormalities can be prevented by taking as many stage 3 measures as possible in addition to Stages 1 and 2 measures. 7. It is essential that managers or supervisors provide leadership in taking action to prevent abnormalities recurring. Discussion The following questions ask you to think about how the ideas in the text could be applied in your company. Some of the ideas may not be relevant to you. Concentrate on what is relevant. Keep notes of your conclusions – you will need them to prepare your action plan afterwards. Where appropriate ask yourself the RADAR questions. Note: Always include in your discussion any figures referred to in the text, if you feel these are relevant to your company. a. Parag. 1: Give some e...
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This note was uploaded on 10/07/2013 for the course MKT marketing taught by Professor Anamika during the Spring '12 term at Punjab Engineering College.

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