Week 6 Striving for Perfection Flashcards
Fifth principal of LEAN
We should strive for all value and no waste no defects.
Getting as close to
perfection as you can, it’s the journey not the destination. Continuously improve.
FMEA
Failure Modes and Effects Analysis
Failure Modes and Effects Analysis (FMEA) answers these 3 questions:
“why is this important to my six sigma project?”
1) What might cause a problem?
2) what is the risk assessment?
3) what are the next steps?
Failure Modes and Effects Analysis (FMEA) sequence of steps define:
1) potential failure modes
2) potential mechanisms of failure
3) potential effects of the failure
4) severity* of the failure
5) probability of occurrence* of failure
6) ease of detecting* the failure
7) Multiply the severity, occurrence, and detection to calculate a risk priority number (RPN)
8) recommended actions to take
Solve priorities using Failure Modes and Effects Analysis (FMEA)
Repetitive issues that the company faces.
Top-down projects management has initiated as improvement projects.
Managements strategic vision and selection of priorities.
Innovation for business growth.
Failure Modes Effects Analysis (FMEA): 3 main issue critieria:
1) Highest Risk priority number (RPN)
2) Major pain point that operators continue to complain about
3) Main cause of downtime reported repeatedly
Failure Modes and Effects Analysis (FMEA), prevention includes:
- Error proofing
- Current process capabilities
- Mitigation reduces the seriousness of an issue but does not eliminate it.
- Understand main problems and current controls
- Understanding the severity and frequency
- How easy it is to detect
Failure Modes and Effects Analysis (FMEA): RPN scoring
Use 1 to 10 scale, if all is well, severity = 1, occurrence = 1, detection = 1 RPN = 3.
At the other extreme, 10x10x10=1000.
Failure Modes and Effects Analysis (FMEA): Mitigation vs. Prevention
Mitigation reduces the seriousness but will not eliminate it (firefighting).
Prevention is almost always a better policy, it helps make a process defect free.
Solve a chaotic assembly-line problem
Poka-Yoke, Shigeo Shingo developed a simple solution to a chaotic assembly-line problem.
Poka-Yoke is
error-proofing a process (not person). Was, originally “idiot proof”.
Error proofing two springs was from
Poka-Yoke, example. Tray came with two springs eliminating the mistake of not installing spring.
FMEA, RPN high RPN can be solved by
Poka-Yoke, if I have a high degree of detection trouble can be solved with Poka-yoke.
Error proofing diesel and unleaded was done by?
Poka-Yoke is two different size diameter nozzels.
Error proofing surgery errors was done by?
Poka-Yoke simply writing on the patients body with patient signature.
Error proofing RX fill was done by?
Poka-Yoke screening medication conflicts before filling script by reviewing current meds.
Error proofing shipping and transportation by?
Poka-Yoke with bar coding.
Error proofing data input was done by?
Poka-Yoke with input requirements before moving to the next field or completing a form.
Poka-Yoke example for parts
System of checks to ensure part falls within spec.
Poka-Yoke example for machining
Triggers and sensors that prohibit a machine from cycling
5S name the words
- Sort
- Set in place
- Shine
- Standardize
- Sustain
The goal of 5S can be summarized as…
“A place for everything and everything in its place.”
JIT is
Just in time and the reason 5S was created.
