D 5 Choose Verify Permanent Corrective Actions D

D 5 Choose & Verify Permanent Corrective Actions

D 5 Choose & Verify Permanent Corrective Actions Often the solution or solutions become obvious once the root causes are known. § However, sometimes, a systematic approach is needed to use the root cause analysis to develop a solution. If the solution is obvious, select the best solution or mix of solutions that will lead to a robust, yet cost-effective, resolution. § If solutions are not yet evident, follow the data trail. When solutions are not obvious, often the root cause has not been found.

D 5 Choose & Verify Permanent Corrective Actions A USA business survey reported 20% - 30% of corrective actions were “worker reprimanded and retrained” Telling someone to “be more careful” or “pay attention” is not effective, especially in repetitive high pressure environments. Operator/all operators retrained to SOP Operator reprimanded Poka yoke introduced Operator spoken to Revised/updated SOP procedure Operator error/fault Implemented visual controls Changed process to eliminate error

D 5 Choose & Verify Permanent Corrective Actions Criteria for choosing the best solution: § § Practical - The 8 D team should be able to implement the solution practically. Feasible - The solution must be feasible. Cost effective - Implementing and using the solution must be cost effective. Robust - The solution shouldn’t fail when used in production. Robustness of the solution is an essential characteristic (error proofing, impact-effort matrix) § Team Champion must have full buy-in to Permanent Corrective Actions and facilitate their implementation.

D 5 Choose & Verify Permanent Corrective Actions Error Proofing § Error Proofing is an approach that takes us towards right-first-time quality. § Errors cause Defects and these occur when process mistakes are allowed to reach the next step in the process (i. e. the customer). § Remember - to know if there’s a defect – the standard must be clear! § The aim of Error Proofing is to design the process so that mistakes can be detected & corrected at the source – the ideal is to prevent! § Your Takesupplier into consideration these 3 rules: You Don’t accept a defect Don’t create a defect Your customer Don’t forward a defect

D 5 Choose & Verify Permanent Corrective Actions Low Awareness • Error occurs and we are made aware – however error can be progressed • Error Proofing Effectiveness High Detection Prevention Error occurs but containment in place to stop automatic progression • Error can’t physically be created or progressed

Activity Split into your teams For each one – state what the solution is raising awareness of/detecting/preventing What examples can you think of under the categories below?

D 5 Choose & Verify Permanent Corrective Actions Low Error Proofing Effectiveness Awareness • Error occurs and we are made aware – however error can be progressed High Detection • Error occurs but containment in place to stop automatic progression Prevention • Error can’t physically be created or progressed Factors for consideration when choosing an appropriate solution: § Likelihood/Frequency of error occurrence § Severity/Impact of error Be careful to not over/under-engineer the solution!!!

D 5 Choose & Verify Permanent Corrective Actions ERROR PROOFING METHODS: VISIBILITY / COLOUR FEEDBACK / ALARMS CONSTRAINTS / GO – NO GO

D 5 Choose & Verify Permanent Corrective Actions Error Proofing – Be Careful of Over/Under-Engineering!!!

D 5 Choose & Verify Permanent Corrective Actions It is necessary to establish that the solution will make the problem go away without leading into other unwanted issues. § The solution is first to be tried on small lots to validate that it has indeed solved the problem prior to full implementation. § A design verification test (DVT) and/or a reliability demonstration test (RDT) may be required depending on the solution.

D 5 Choose & Verify Permanent Corrective Actions Key points: § Do not develop solutions that do not consider the practical aspect of production. § Never forget to consider the capability of manufacturing (machines, people, etc…) when developing solutions. § Never forget to consider the capability of the supplier when developing new parts or tighter specifications. § Has the solution passed the tests of practicality, feasibility and cost effectiveness? § Is the solution robust and capable of preventing a recurrence of the problem? § Does the ROI (return on investment) or the payback of the solution justify the cost of implementing the solution? § Can the solution be implemented within the required deadline? § Is training required? If yes, have plans been generated?

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