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PA - Problem Analysis: Use This App To Perform KT Problem Analysis and Find The Cause of Tough Problems
PA - Problem Analysis: Use This App To Perform KT Problem Analysis and Find The Cause of Tough Problems
Use this app to perform KT Problem Analysis and find the cause of tough problems.
Problem Overview
Current Status
IS IS NOT
WHAT
Possible Causes
Possible Cause A:
obsolete design of slider subassembly for splining operation. The slider subassembly tooling under scope was replaced by a newest design ZG-911-971-000,
it was created and developed in Eschen by Bertram Hartmann since 12.07.2016. It was modified by maerob on 05.01.2018 to specify the planarity tolerace
on the drawing.
WHEN
When First? in CW18/2019 --> 29.04.19, 01.02.2013 up to 28.04.19 it does not explain both IS
Monday, early shift night shift and IS NOT conditions, since
before and after the first
incident, the same old
design have been used all
the time.
When Since? 3 more incidents: all the noon and night shifts it does not explain both IS
CW21/2019 --> Sa. from production runs and IS NOT conditions, since
25.05.2019 at 8:49 am between 29.04.2019 noon before and after the second,
CW25/2019 --> Th. shift and each of the other 3 third to first incident, the
20.06.2019 at 4:49 am incidences and after the last
Possible Cause B:
strong organizational change in the middle management of production responsible for M1889 since February 2019 driven by poor change management
strategies. Responsability of most experienced, senior production supervisor was splitted to full focus on M2163 as line sheriff since February 2019. The
other 3 final assembly lines were delegated to 2 new unexperienced production supervisors. The production supervisor of M1889 started in March 2019 as
production coach and then he left the company mid August 2019.
Possible Cause D:
a new process module known as HSO (high speed oscilation) was integrated to the final assembly line M2163 mid of February 2019, which led to a
relocation from some product types running initially at the M2163 to alternative machines like M1889. This relocation was done during March 2019,
whereas the integration of the new product types was done by a new team of process engineers. The interaction of the new parameter data settings with
competing mechanical parameters from other serial products is not done by the same process engineer who integrated the product, but by the production
shift leader with escalation to production supervisor and process engineer for serial production. Integration process engineers are leaded by manager A
(non-spanish speaking, lack of management experience) and serial production engineers are leaded by manager B (native speaker, lack of management
experience). Communication issues between production and the both new process engineering teams could lead to process or mechanical parameter
incompatibility of new projects with serial products.
WHEN
When First? in CW18/2019 --> 01.02.2013 up to
29.04.19, Monday, 28.04.19 night shift
early shift
Experiment reset all relevant process parameters of splining process engineer @ CW35/2019
operation in M2672 before the integrations
done by beginning March 2019 and verify the
results.
Try a Fix and Monitor reliability analysis to calculate the MTBF before maintenance engineer @ CW52/2019
and after the proposed fix.