PROBLEM SOLVING
What is a problem?
A problem is the GAP between,
The current situation and
Customer satisfaction Defined as discrepancy between an existing standard or expectation and the actual situation
What is problem solving?
8.5.2.1 of TS16949 The organization shall have a defined
process for problem solving leading to
root cause identification & elimination
What is a tool?
Problem solving tools
Flow chart Pareto chart Control chart Tree diagram Check sheet CE diagrams Affinity diagram Matrix diagram Arrow diagram Histogram Scatter diagram Relationship diagram
Matrix data analysis
Decision tree
Capability study
Brainstorming
Core steps of problem solving
1. Define the problem 2. Containment actions 3. Root cause analysis 4. Corrective actions
5. Validate actions
6. Institutionalize or Standardize
1.Define the problem (5W-2H)
1 What What is the problem?
2
3
Who
Where
Who is concerned?
Where does it occur?
4
5
When
Why
When did it happen?
Why is it a problem?
1
2
How
How many
How customer discovered?
How many? (Quantity affected)
2.Containment actions
2.Containment actions
1. See the possibilities of containing the problem at source or immediately after the source 2. Verify the stocks in pipe line for the problem, Customer end, In-transit (between supplier & customer) Work In Progress (WIP) Incoming stage Sub-supplier 3. See other alternates available till problem is solved
3.Root cause analysis
Cause
Effect
3.Root cause analysis
There are several tools available to solve problem and get to the root cause. Their use is dependent upon the complexity of the process, the type of Failure mode, Fit, Function, or Finish, and the system used to measure the specific characteristic that failed which will be attribute or variable data.
4.Corrective actions
List root causes
Think of poka-yoke for root causes
Brainstorm possible solutions and select the most effective, efficient and cost effective solution. Determine if a trial run is needed to confirm and test the proposed solution to verify it is effective and has no other adverse effects.
5.Validate (corrective actions)
Monitor effectiveness of actions (defects occurrence) for three months
If effective, feedback to customer & close If not effective, go back to brainstorming Monitor recurrence for next 12 months (3 months effectiveness + 9 more months)
6.Institutionalize or Standardize
Process flow Work instruct Forms Supplier list PFMEA Procedures Tool drawings Skill matrix Audit plans Control plan Check sheets Product drawings
Past trouble data base
Lessons learnt
Training manual
OJT
What is a QC story?
A past happening which helped QC circles to solve a problem using PDCA cycle, shared to rest of the team as a story to, Motivate other teams Improve knowledge Support to come out of issues
Form a team
Form team comprising personnel from, Caused process,
Production,
Quality & From other process as needed.
Action plan
PROJECT : DIA 3 MM DRILL BREAKAGE IN AVP51 HSG TEAM : Narayanan (Mfg), Gopalan (Mfg), Venkatesan (Mfg), Srinivasan (Mfg), Parandhaman (Mfg), Govindhan (Mfg), Vasudevan (QA) DATE
Date
S.NO TASK RESPONSIBILITY START DATE FINISH DATE JAN FEB MAR APR MAY JUNE JULY
1 2 3 4 5 6 7
PROBLEM (Identify & Define) CONTAINMENT ACTIONS ROOT CAUSE ANALYSIS CORRECTION VALIDATION STANDARDISATION CONCLUSION / EFFECTIVENESS
Mr.Narayanan Mr.Gopalan Mr.Venkatesan Mr.Srinivasan Mr.Parandhaman Mr.Govindan Mr.Vasudevan
Plan
Completed
Pareto of a machined part
PERIOD FROM APRIL TO DECEMBER (9 MONTHS)
225 200 175
QUANTITY
83.54 69.35 52.9
88.87
93.31
100
100
90
80 70
150
125 100 75 50
Total 225 Nos Rejection In 9 Months
60
50
40 30
82
36.44
37 37 32
20
25
0
DIA 3 DRILL BROKEN C V O/SIZE DIA 39 O/SIZE C V DEPTH MORE
12
M8 TAP BROKEN
10
C V UNWASH
15
OTHERS
10 0
Identify the problem
(82 / 225 nos) OF
TOP-1 identified in this case
REJECTION DUE TO DIA 3MM DRILL BROKEN
Top-1 Problem Monetary Loss
PERIOD FROM APRIL TO DEC (9 Months)
100000
RS RS. 77446 COST OF DRILL
50000 0
RS. 16296
TOTAL LOSS = RS. 93,742
Define the problem (5W-2H)
1 2 3 4 5 1 2
Who is concerned?
Production Dia 3 mm drill breaks In Shang-Nong CNC m/c Happens randomly
What happened (or) What is the
problem?
Where does it occur? When did it happen? Why is it a problem? How customer discovered? How many? (Quantity affected)
Contributes significantly for higher rejection
Internal problem 82 nos in 9 months (9 per month)
Data collection for the problem
On the shop (Gemba) Observation
1. BREAKAGE IN NEW AND REGROUND DRILL 2. BURR CLOGGING IN DRILL FLUTE 3. BREAKAGE IN INITIAL CUT AND ALSO IN MORE DEPTH
Brainstorming to generate ideas
TOTAL NO.OF IDEAS GENERATED - 27
IDEAS SHORT LISTED BY TEAM MEMBERS EXPERIENCE AND GEMBA VISIT
- 21
Ideas (Potential causes) Shortlisted-21
SL.NO: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PARAMETER TURRET I NDEXI NG SPI NDLE RUNOUT COOLANT FLOW I MPROPER GRI NDI NG WRONG HANDLI NG WRONG LOADI NG WRONG OFFSET NORMS NOT MAI NTAI NED TOOL GEOMETRY TOOL BEND I NADEQUATE FLUTE LENGTH TOOL GRADE WRONG PROCESS WRONG PARAMETER I MPROPER FI XTURE COOLANT GRADE GRI NDI NG WHEEL GRADE TOOL CLAMPI NG BLOW HOLE PRESENT POOR MACHI NABI LI TY COOLANT CONDI TI ON
Potential causes categorized
MAN
IMPROPER GRINDING WRONG OFFSET WRONG LOADING WRONG HANDLING SPINDLE RUNOUT
MACHINE
TURRET WRONG INDEXING COOLANT FLOW
NORMS NOT MAINTAINED IMPROPER FIXTURE COOLANT GRADE COOLANT CONDITION
GR.WHEEL GRADE WRONG PARAMETER WRONG PROCESS TOOL CLAMPING
DIA 3 DRILL BREAKAGE
TOOL GEOMETRY TOOL BEND WRONG GRADE INADEQUATE FLUTE LENGHT
BLOW HOLE
POOR MACHINABILITY
METHOD
MATERIAL
TOOL
# 1 2
PARAMETER TURRET INDEXING SPINDLE RUNOUT COOLANT FLOW IMPROPER GRINDING WRONG HANDLING WRONG LOADING WRONG OFFSET NORMS NOT MAINTAINED
TOOL VISUAL DIAL VISUAL VISUAL/FEELING SYSTEM SKILL SKILL SYSTEM
CHECK GEMBA CHECK CHECK SHEET GEMBA GEMBA
STATUS SIGNIFICANT SIGNIFICANT SIGNIFICANT SIGNIFICANT INSIGNIFICANT
Initial Validation of Potential Causes
Reduced from 21 Potential to 10 Significant
3 4 5 6 7 8 9 10 11 12
SKILL MATRIX FORM INSIGNIFICANT SKILL MATRIX FORM INSIGNIFICANT TOOL NORMS SHEET INSIGNIFICANT
TOOL GEOMETRY
TOOL BEND INADEQUATE FLUTE LENGTH TOOL GRADE WRONG PROCESS WRONG PARAMETER IMPROPER FIXTURE COOLANT GRADE GRINDING WHEEL GRADE TOOL CLAMPING BLOW HOLE PRESENT POOR MACHINABILITY COOLANT CONDITION
PROFIL PROJ.
DIAL VERNIER BY RESULT SYSTEM STANDARDS DESIGN STANDARD STANDARD VISUAL/FEELING BY CUTTING BY INSPECTION VISUAL
CHECK SHEET
CHECK SHEET CHECK SHEET INSPECTION PROCESS SHEET PROCESS SHEET
SIGNIFICANT
SIGNIFICANT SIGNIFICANT SIGNIFICANT INSIGNIFICANT INSIGNIFICANT INSIGNIFICANT
13
14 15 16 17 18 19 20 21
SYSTEM SYSTEM CHECK SHEET VISUAL REPORT CHECK SHEET
INSIGNIFICANT INSIGNIFICANT SIGNIFICANT INSIGNIFICANT INSIGNIFICANT SIGNIFICANT
Significant Causes (10) Categorized
MAN MACHINE
SPINDLE RUNOUT TURRET WRONG INDEXING IMPROPER REGRINDING COOLANT FLOW
DIA 3 DRILL BREAKAGE
TOOL CLAMPING INADEQUATE FLUTE LENGHT TOOL GRADE TOOL BEND TOOL GEOMETRY
COOLANT CONDITION
METHOD
TOOL
Detailed validation Cause-1
DIA 3 DRILL BREAKAGE TOOL GEOMETRY
TOOL
I.VALIDATION
DIMENSION
POINT ANGLE HELIX ANGLE
SPEC
130 DEG 40 DEG
22.01.02 23.10.02 24.10.02
130 40 129 40 130 41 II.CONCLUSION CAUSE IS NOT SIGNIFICANT
Detailed validation Cause-2
MACHINE
TURRET INDEXING
DIA 3 DRILL BREAKAGE
I.VALIDATION TURRET INDEX STATUS I SHIFT STATUS SHIFT II 22.01.02 OK OK 23.01.02 OK OK 24.01.02 OK OK 25.01.02 OK OK II.CONCLUSION CAUSE IS NOT SIGNIFICANT
Detailed validation Cause-3
MACHINE
SPINDLE RUNOUT
I.VALIDATION
RUNOUT SPEC. 0.01 SPINDLE 1 0.01 SPINDLE 2 0.01 SPINDLE 3 0.01 SPINDLE 4 0.01 SPINDLE 5 0.01 SPINDLE 6 0.01
DIA 3 DRILL BREAKAGE
II.CONCLUSION CAUSE IS NOT SIGNIFICANT
Detailed validation Cause-4
MACHINE
COOLANT FLOW
I.VALIDATION
DIA 3 DRILL BREAKAGE
SPECIFICATION (DISCHARGE) > 10 LPM > 10 LPM
ACTUAL 2.2LPM 2LPM
VARIANCE 7.8LPM 8LPM
II.CONCLUSION CAUSE IS SIGNIFICANT
Detailed validation Cause-5
DIA 3 DRILL BREAKAGE
TOOL BEND
I.VALIDATION
TOOL
T2 0.07 T3 0.04 T4 0.05 T5 0.02 T6 0.08 T7 0.05 T8 0.03 T9 0.02 T 10 0.05
SPEC 0.08 MM
T1 0.02
II.CONCLUSION
CAUSE
5 IS NOT SIGNIFICANT
Detailed validation Cause-6
DIA 3 DRILL BREAKAGE
TOOL GRADE
I.VALIDATION
TOOL
DI
OK (200)
MAKE TITEX
D2
NOT OK (133)
D3
NOTOK (175)
D4
NOTOK (46)
D5
OK (200)
RD ENGG. OK
(200)
OK (200)
NOTOK (105)
OK (200)
NOTOK (113)
0K (200)
OK (200)
0K (200)
NOTOK (52) II.CONCLUSION CAUSE
IT
NOT OK (75)
6 IS SIGNIFICANT
Detailed validation Cause-7
DIA 3 DRILL BREAKAGE
INADEQUATE FLUTE LENGHT
I.VALIDATION
TOOL T2 64.8 T3 65.0 T4 64.6 T5 65.1
SPEC 64MIN
T1 65.2
II.CONCLUSION CAUSE
7 IS NOT SIGNIFICANT
Detailed validation Cause-8
DIA 3 DRILL BREAKAGE
TOOL CLAMPING
METHOD
I.VALIDATION ACCESSORIES STATUS CHECK METHOD
HOLDER
TAPER ADAPTOR COLLET
NO DAMAGES
NO DAMAGES NO DAMAGES NO DAMAGES
VISUAL
VISUAL VISUAL VISUAL II.CONCLUSION
CAUSE
8 IS NON SIGNIFICANT
Detailed validation Cause-9
DIA 3 DRILL BREAKAGE
COOLANT CONDITION
I.VALIDATION
METHOD Day-1 Day-2 Day-3 Day-4 Day-5 NO NO NO NO NO
II.CONCLUSION
FILTERATION SEDIMENT
CAUSE
9 IS NOT SIGNIFICANT
Detailed validation Cause-10
MAN
IMPROPER GRINDING
I.VALIDATION DIMENSION POINT ANGLE HELIX ANGLE SPEC 130 DEG 40 DEG 22.01.02 130 40 23.10.02 129 39 24.10.02 130 40
DIA 3 DRILL BREAKAGE
II.CONCLUSION
COATING OF DRILL AFTER REGRINDING CANT BE DONE
CAUSE
10 IS SIGNIFICANT
Significant Causes
Reduced from 10 to 3
SL.NO 1 2 3 4 5 6 7 8 9 10 PARAMETER TURRET INDEXING SPINDLE RUNOUT COOLANT FLOW TOOL GEOMETRY TOOL BEND IN ADEQUATE FLUTE LENGTH TOOL GRADE TOOL CLAMPING COOLANT CONDITION IMPROPER GRINDING TOOL VISUAL DIAL VISUAL P. PROJECTOR DIAL VERNIER BY RESULT STATUS INSIGNIFICANT INSIGNIFICANT SIGNIFICANT INSIGNIFICANT INSIGNIFICANT INSIGNIFICANT SIGNIFICANT
VISUAL/FEELING INSIGNIFICANT VISUAL P. PROJECTOR INSIGNIFICANT SIGNIFICANT
-
Significant Causes (3) Categorized
MAN
IMPROPER GRINDING
MACHINE
COOLANT FLOW
DIA 3 DRILL BREAKAGE
TOOL GRADE
TOOL
Root Cause-1
MACHINE
COOLANT FLOW
DIA 3 DRILL BREAKAGE
CAUSE 1
COOLANT FLOW
WHY ?
INSUFFICIENT DISCHARGE
WHY ?
LOW CAPACITY PUMP
WHY ?
MACHINE DESIGN
Root Cause-2
DIA 3 DRILL BREAKAGE
2
TOOL GRADE
TOOL CAUSE 2
TOOL GRADE
WHY ?
WRONG TOOL SELECTION
WHY ?
NO AWARENESS
WHY ?
Root Cause-3
MAN
3
IMPROPER GRINDING
DIA 3 DRILL BREAKAGE
CAUSE 3
IMPROPER REGRIDING
WHY ?
NO COATING AFTER REGRINDING
WHY ?
NO FACILITY
WHY ?
Actions for Root Causes
Root Cause-1 Before / After
BEFORE - SHANG NONG
ADVANTAGES OF AMS OVER SHANG NONG
SHANG NONG MACHINE
FEATURES
AMS MACHINE
ADVANTAGE
COOLANT DISCHARGE
20 LTS PER MIN.
2 LTS. PER MIN.
MORE COOLANT / AVOID HEAT
AFTER - AMS
NOZZLE
MULTI NOZZLE
SINGLE NOZZLE
AVOID BURR CLOGGING
NOZZLE DIAMETER
5.5MM
8MM
MORE PRESSURE
PRESSURE
3 BAR
NEGLIGIB LE
FLUSHING BURR EFFECTIVELY
COOLANT TANK CAPACITY
500 LTRS
45 LTRS
MORE COOLANT CAPACITY
PPM COMPARISION - CAUSE -1Coolant flow
3000
2000 PPM 1000 0 MACHINE SHANG NONG AMS 2745 1935
Root Cause-2 Before / After
ACTION : TITEX MAKE TO RD ENGG. MAKE
MAKE TITEX POINT ANGLE 130 DEG. HELIX ANGLE MATERIAL COATING 40 DEG. HSS-CO HSS
RD ENGG. 133 ~ 137 DEG. 35 ~ 37 DEG.
TINAL FUTURA COATING TITANIUM NITRATE
PPM COMPARISION - TOOL GRADE
1935 2000 1500
PPM
1000
410
500
0 TOOL GRADE TITEX RD ENGG.
PPM Trend
REGROUND DRILL
QCC COMPLETED
2500
2000
PPM
2222
1500 1000 500
0
968
878
571 410
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT
185
Institutionalize or Standardize
# SOP revised (Sop No. 0218 dt. 26.06.02)
# Tooling plan revised.
