Basic Checks Current Condition Was the Standard Operating

Basic Checks Current Condition ü Was the Standard Operating Procedure being followed properly? ü Is the Operator correctly trained and do they have the skills to do this job? ü Is the equipment configured with the standard settings for this job? ü Do the raw materials meet the required specifications for the job? ü Has the problem been safely contained? ü Is the difference between the current & required conditions understood? ü Have obvious solutions been identified and tried? ü Is there an obvious cause? (look upstream and downstream) ü This problem occurred because of…. ? Solution Hierarchy Mistake Proofing ü Eliminate the root cause to prevent the issue from re-occurring again. Which conditions are obviously contributing to the symptoms? MAN Skills Experience Current Condition METHOD SOP’s One Point Lessons Forced Control makes it impossible to make a mistake. Administration Controls Personal Protective Equipment ü How has the solution been tested? ü How will it prevent re-occurrence? Effectiveness Substitution Engineering Controls MATERIAL Specification Out of Date? ü There are four approaches. . . Elimination Isolation CC MACHINE Condition Settings Shut Down when rejects are found, Supervisor re-starts. Warning by use of sounds or lights or both Sensory Alert by use of colour, sound, vibration, visuals, 5 S. Target Condition ü Revert to Standard Conditions ü Is the settings correct? ü Are procedures being followed? Define The Problem Restore Standard Conditions Repair Equipment Problems Incremental Improvements TC Target Condition Verify New Process ü How have we eliminated the problem? ü Did our countermeasures work? ü Have we verified elimination of the problem has been achieved? ü Do we need to update procedures? ü Do we need to train people to the new methods and machine settings? ü Are training records up to date? ü Do we need to review our Preventative Maintenance plans? ü Are Risk Assessments required? ü How will we audit and sustain the changes we have made? Document created by and contents copyright of Incremental Improvements Australia Pty Ltd, PO Box 1178, Maroochydore, Queensland 4558, Australia. 1300 00 IIAU.