Analyse

Cause and Effect Analysis: The team carried out a cause and effect analysis on all of the issues that were identified during the measure phase.  We performed this at a scheduled workshop that was an extension of the weekly team meeting.  We used the standard categories of this tool to try and understand the root cause of each issue: Man Method Machine Mother Nature Materials Measurements The team found this tool to be really useful as it helped us to identify a root cause for each issue and propose a recommendation.  Visual Analysis of Data:  Following the cause and effect analysis we gathered all of the information and broke each issue into three categories - Observation, Risk & Recommendation. The team put these into a powerpoint presentation to visually outline each issue.  We found this to work well as it helped us to visually display the risks identified and recommendations to improve them.  We used the following template to show this information. Process Map Review and Analysis: The team mapped the process during the Define/Measure phase.  It was now time to carry out a robust review and analysis on the map.  The team also identified where there are risks to the process during each step using a basic risk analysis tool.  This worked well for the group and created a lot of discussion about what the risks during each step of the process are. Ideal State process sequence re-mapped and documented: The ideal state process sequences were re-mapped and documented following the review and analysis.  As the team identified where there are risks to the process during each step, we decided to highlight these using warning symbols. This will allow the team to develop the best practice method for each step involved whilst taking these risks into consideration. You can see a screenshot below for each of the symbols that we used and an example of the process map. Key findings of Analyse phase: As a group we conducted an exercise to summarize our findings during the analyze phase of the project, so we would remain focused as we prepared for the improve phase. We identified 8 key improvements that we will focus on during the improve phase. ·         Standard  procedure should be trialed and the best practice methods recorded during the Kaizen event (improve phase) ·         Ownership of Engineering task which identified waste in waiting should be transferred to   production  ·         Standard procedure for the storage of parts to be developed ·         5s aids to be sourced to store parts and equipment ·         Standard for the transportation and cleaning of parts to be prepared ·         Engineering solutions (mistake proofing) required for a number of issues identified  ·         SOP’s need to be improved and made more visual The improve phase of the project will be carried out as a week long Kaizen event where the team will work together to identify solutions to problems that have been recorded and prepare any necessary documentation that is required.  This is due to take place wk commencing 25th March.