The document discusses various root cause failure analysis techniques including: 5 Whys method, Ishikawa diagrams, failure mode analysis, statistical analysis, and selecting/prioritizing corrective actions. It provides examples of root cause analyses including issues with Boeing C-17 landing gear sensors, Blue Screen of Death software errors, conveyor drive failures, and mobile hydraulic truck pump leakage. The key lessons are the importance of thorough problem definition, dedicated investigation, not assuming initial causes are correct, and using data to identify root causes and prevent recurrence.
Abstract
The purpose and the objective of the research is to present the problem-solving method used by a successful company while acquiring an invaluable "gift" - a complaint. Service economics is growing in importance, and satisfying customers is a major objective of enterprises. This paper has focused on 8D methodology which is an 8 disciplinary approach. It consists of 8-steps to be followed by a quality improvement team for problem-solving as well as for product and process improvements. Improving the quality of the use of the 8D methodology.
KAIZEN: A Lean Manufacturing Techniquevivatechijri
Now-a-days the ultimate goal of all industries is to enhance productivity through simplified system
and incremental improvements by applying some modern available techniques. At present, many manufacturing
companies are facing problems such as high quality rejection, high inventories, high lead time, high costs of
production, and inability to cope with customer orders. By implementing and practicing the lean production
system many problems can be solved without employing high-tech and high-touch approaches but by involving
people on the shop floor in Kaizen activities. For continuous improvement in an organization, Japanese
philosophy Kaizen is very popular. Flawless concepts of Kaizen methodology and proper implementation of tools
can lead to a successful kaizen program in a company. Kaizen is one of the powerful tools of lean manufacturing.
Kaizen refers to continuous improvement in performance, cost and quality. Kaizen ensures that manufacturing
processes become leaner and fitter, but eliminate waste (problem) where value is added. The main objective of
this paper is to provide a background on kaizen, present an overview of kaizen concepts that are used to transform
a company into a high performing lean enterprise.
Managerial and Technical skills of supervisorsNabila Naik
Supervisors work closely with employees of any given business. While some supervisors act as managers and tell people how to do their work, others work as part of a team and supervise with respect, loyalty and a positive tone of voice. It is often the small characteristics that define a good and enjoyable employee supervisor. Rather than telling people how to work, a good supervisor serves as an inspiration and provides guidance for hardworking employees.
To get more for less is the Philosophers' Stone – for managers, politicians and economists. This book explains the practical steps that operational managers can take to improve productivity in all types of business and in the public and not-for-profit sectors. It brings together good practice from different managerial disciplines and pays particular attention to the theory and application of lean in manufacturing, services and administration.
Collinson Grant has helped lots of firms renew themselves. Our work has gone under many descriptions: improving gross margins, restructuring, cost reduction, applying lean techniques, and turning around performance. We have helped managers achieve results quickly to respond to changes in the market and the activities of competitors, or to restore profitability and satisfy the demands of investors. Our basic goal remains unchanged: to achieve better financial results by improving effectiveness, removing wasted effort, and making fundamental improvements in productivity to help cope with new, more challenging circumstances. Find out more at www.collinsongrant.com or email pmackenzie@collinsongrant.com
How to Introduce Operational Excellence in your Organisation?Tina Arora
This presentation will help you present to the management the need and benefits of introducing Operational Excellence as a department in your Organisation.
It can be modified to suit the advocacy in any industry - be it Financial services, BPO, LPO, KPO, Domestic call centres, Manufacturing, Consumer Goods, Retail, etc.
Abstract
The purpose and the objective of the research is to present the problem-solving method used by a successful company while acquiring an invaluable "gift" - a complaint. Service economics is growing in importance, and satisfying customers is a major objective of enterprises. This paper has focused on 8D methodology which is an 8 disciplinary approach. It consists of 8-steps to be followed by a quality improvement team for problem-solving as well as for product and process improvements. Improving the quality of the use of the 8D methodology.
KAIZEN: A Lean Manufacturing Techniquevivatechijri
Now-a-days the ultimate goal of all industries is to enhance productivity through simplified system
and incremental improvements by applying some modern available techniques. At present, many manufacturing
companies are facing problems such as high quality rejection, high inventories, high lead time, high costs of
production, and inability to cope with customer orders. By implementing and practicing the lean production
system many problems can be solved without employing high-tech and high-touch approaches but by involving
people on the shop floor in Kaizen activities. For continuous improvement in an organization, Japanese
philosophy Kaizen is very popular. Flawless concepts of Kaizen methodology and proper implementation of tools
can lead to a successful kaizen program in a company. Kaizen is one of the powerful tools of lean manufacturing.
Kaizen refers to continuous improvement in performance, cost and quality. Kaizen ensures that manufacturing
processes become leaner and fitter, but eliminate waste (problem) where value is added. The main objective of
this paper is to provide a background on kaizen, present an overview of kaizen concepts that are used to transform
a company into a high performing lean enterprise.
Managerial and Technical skills of supervisorsNabila Naik
Supervisors work closely with employees of any given business. While some supervisors act as managers and tell people how to do their work, others work as part of a team and supervise with respect, loyalty and a positive tone of voice. It is often the small characteristics that define a good and enjoyable employee supervisor. Rather than telling people how to work, a good supervisor serves as an inspiration and provides guidance for hardworking employees.
To get more for less is the Philosophers' Stone – for managers, politicians and economists. This book explains the practical steps that operational managers can take to improve productivity in all types of business and in the public and not-for-profit sectors. It brings together good practice from different managerial disciplines and pays particular attention to the theory and application of lean in manufacturing, services and administration.
Collinson Grant has helped lots of firms renew themselves. Our work has gone under many descriptions: improving gross margins, restructuring, cost reduction, applying lean techniques, and turning around performance. We have helped managers achieve results quickly to respond to changes in the market and the activities of competitors, or to restore profitability and satisfy the demands of investors. Our basic goal remains unchanged: to achieve better financial results by improving effectiveness, removing wasted effort, and making fundamental improvements in productivity to help cope with new, more challenging circumstances. Find out more at www.collinsongrant.com or email pmackenzie@collinsongrant.com
How to Introduce Operational Excellence in your Organisation?Tina Arora
This presentation will help you present to the management the need and benefits of introducing Operational Excellence as a department in your Organisation.
It can be modified to suit the advocacy in any industry - be it Financial services, BPO, LPO, KPO, Domestic call centres, Manufacturing, Consumer Goods, Retail, etc.
Highlights the details of Origin Metrology Group's preventive and predictive maintenance support options as well as our engineering philosophies and methodologies associated with our services.
How to survive in any business requires unending improvement and elimination of waste in time,inventory,materials,delays,etc. Report is courtesy of www.JoeMyRealtor.com and www.ValenciaAndStevensonRanchHomes.com
Yellow belt process improvement training and certification moduleVishy Chandra
Free Yellow Belt Training in Process Improvement for all those who want to get started with a formalized approach to process improvement.
Module contains Kaizen, PDCA, 8D, TOC, Lean and Six Sigma. By the end of the module, the trainee will be able to identify a project opportunity in their organization and that will be eligible for free certification.
The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
Multi criteria Decision model (MCDM) for the evaluation of maintenance practi...IJERA Editor
The perceptible impact of Total Productive Maintenance (TPM) lies in raising productivity standards, gaining
profitability, and improving the quality besides cutting down the non value added costs greatly. This paper is
an attempt to provide a frame work and pragmatic approach in implementation of TPM. A number of novel
success factors or practices that are responsible for the decisive role to overture the process are identified.
These practices are interchangeably called as sub-attributes. These practices must have evolved from different
strategies. The sub-attributes are quantified using least square multi attribute decision model (LSMADM) for
three alternatives strategies viz. corrective maintenance, reliability centered maintenance(RCM), and TPM. Any
sub-attribute irrespective of its own high or low relative score among the number of sub attributes is evaluated
over three alternative strategies. To implement any sub-attribute, an investigation of its highest relative score
for given alternatives will guide the managers to opt the best alternative. The best practices must come from
different strategies to get most optimal results. The priorities established using LSMADM will act as base line
to implement the industrial activities in a more systematic and balanced way to gain far-reaching optimized
productivity and quality standards. The higher priority task will be given higher consideration in terms of
committing the resources vis a vis less priority task. This will aid in orienting the collective efforts for optimal
outcomes.
Total Productive Maintenance - A Systematic Reviewijsrd.com
TPM is an effective tool and a practical technique, which is aimed at maximizing the effectiveness of the facility by minimizing the downtime of machine, production losses and the material, production losses that occurs during the continuous production process. This also increase the working efficiency and productivity of the employee and a positive inclination is registered in the overall environment of a company. This paper presents the literature review of total productive maintenance which is a positive approach for solving the manufacturing problem, also gives the objective of TPM, a detail about a six big losses, 8 pillar of TPM also give the tool used for improvement, implementation stages, methodology for calculating the overall equipment efficiency and also give the direct and indirect benefits of TPM. The aim of this paper is to study the TPM concept and its implementation program which gives a successful improvement in overall equipment efficiency.
Highlights the details of Origin Metrology Group's preventive and predictive maintenance support options as well as our engineering philosophies and methodologies associated with our services.
How to survive in any business requires unending improvement and elimination of waste in time,inventory,materials,delays,etc. Report is courtesy of www.JoeMyRealtor.com and www.ValenciaAndStevensonRanchHomes.com
Yellow belt process improvement training and certification moduleVishy Chandra
Free Yellow Belt Training in Process Improvement for all those who want to get started with a formalized approach to process improvement.
Module contains Kaizen, PDCA, 8D, TOC, Lean and Six Sigma. By the end of the module, the trainee will be able to identify a project opportunity in their organization and that will be eligible for free certification.
The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
Multi criteria Decision model (MCDM) for the evaluation of maintenance practi...IJERA Editor
The perceptible impact of Total Productive Maintenance (TPM) lies in raising productivity standards, gaining
profitability, and improving the quality besides cutting down the non value added costs greatly. This paper is
an attempt to provide a frame work and pragmatic approach in implementation of TPM. A number of novel
success factors or practices that are responsible for the decisive role to overture the process are identified.
These practices are interchangeably called as sub-attributes. These practices must have evolved from different
strategies. The sub-attributes are quantified using least square multi attribute decision model (LSMADM) for
three alternatives strategies viz. corrective maintenance, reliability centered maintenance(RCM), and TPM. Any
sub-attribute irrespective of its own high or low relative score among the number of sub attributes is evaluated
over three alternative strategies. To implement any sub-attribute, an investigation of its highest relative score
for given alternatives will guide the managers to opt the best alternative. The best practices must come from
different strategies to get most optimal results. The priorities established using LSMADM will act as base line
to implement the industrial activities in a more systematic and balanced way to gain far-reaching optimized
productivity and quality standards. The higher priority task will be given higher consideration in terms of
committing the resources vis a vis less priority task. This will aid in orienting the collective efforts for optimal
outcomes.
Total Productive Maintenance - A Systematic Reviewijsrd.com
TPM is an effective tool and a practical technique, which is aimed at maximizing the effectiveness of the facility by minimizing the downtime of machine, production losses and the material, production losses that occurs during the continuous production process. This also increase the working efficiency and productivity of the employee and a positive inclination is registered in the overall environment of a company. This paper presents the literature review of total productive maintenance which is a positive approach for solving the manufacturing problem, also gives the objective of TPM, a detail about a six big losses, 8 pillar of TPM also give the tool used for improvement, implementation stages, methodology for calculating the overall equipment efficiency and also give the direct and indirect benefits of TPM. The aim of this paper is to study the TPM concept and its implementation program which gives a successful improvement in overall equipment efficiency.
Guidelines for Safe Pre-commissioning, Commissioning, and Operation of Proces...Karl Kolmetz
This seminar focuses on the core building blocks of the process unit equipment.
This program will emphasize process unit equipment fundamentals, safe
utilization of these fundamentals by operations and maintenance personnel, and
equipment troubleshooting techniques.
A presentation on TPM and its objectives, goals, benefits, pillars and other aspects have been explored as well as its relation to 5s & visual. In the end, step by step implementation of TPM, losses & OEE, these tools also have been shown & discussed.
Six Sigma (6σ) is a set of techniques and tools for process improvement.
It was introduced by Bill Smith at Motorola in 1986.
It seeks to improve the quality of the output of a process by identifying and removing the causes of defects and minimizing variability in manufacturing and business processes.
Quality Maintenance is an "advanced" pillar of TPM and aims to assure zero defect conditions. Also known as Hinshitsu Hozen in Japanese, it does this by understanding and controlling the process interactions between the 4Ms - manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than screening them out through inspection systems after they have been produced. Controlling quality through its causes is the essence of Quality Maintenance.
Developed by our JIPM-certified TPM Instructor, this presentation teaches the key concepts, principles and philosophy of Quality Maintenance, the 4M conditions that are essential for defect-free production, as well as the step-by-step process for Quality Maintenance.
LEARNING OBJECTIVES
1. Understand the key concepts, principles and philosophy of Quality Maintenance
2. Acquire knowledge on the 4M conditions and the prerequisites for promoting Quality Maintenance
3. Describe the 8-step process of Quality Maintenance and the key analytical tools and techniques
CONTENTS
1. Key Concepts & Philosophy of Quality Maintenance
2. 4M Conditions - The Determinants of Quality
3. The 8 Steps of Quality Maintenance
4. Key Tools & Techniques for Quality Maintenance
5. Towards Excellence in Quality Maintenance
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Optimizing Petroleum Refining Unit Operations Training CourseKarl Kolmetz
Many aspects of petroleum refining operations management can be improved
including, product recoveries, purities and energy utilization, and safety. This
cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
This seminar focuses on the core building blocks of the petroleum refining
process systems, equipment and economics. This program will emphasize the
refining process unit operation fundamentals, safe utilization of these
fundamentals by operations, engineering, maintenance and support personnel.
6th International Conference on Machine Learning & Applications (CMLA 2024)ClaraZara1
6th International Conference on Machine Learning & Applications (CMLA 2024) will provide an excellent international forum for sharing knowledge and results in theory, methodology and applications of on Machine Learning & Applications.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
Traditionally, dealing with real-time data pipelines has involved significant overhead, even for straightforward tasks like data transformation or masking. However, in this talk, we’ll venture into the dynamic realm of WebAssembly (WASM) and discover how it can revolutionize the creation of stateless streaming pipelines within a Kafka (Redpanda) broker. These pipelines are adept at managing low-latency, high-data-volume scenarios.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
HEAP SORT ILLUSTRATED WITH HEAPIFY, BUILD HEAP FOR DYNAMIC ARRAYS.
Heap sort is a comparison-based sorting technique based on Binary Heap data structure. It is similar to the selection sort where we first find the minimum element and place the minimum element at the beginning. Repeat the same process for the remaining elements.
Low power architecture of logic gates using adiabatic techniquesnooriasukmaningtyas
The growing significance of portable systems to limit power consumption in ultra-large-scale-integration chips of very high density, has recently led to rapid and inventive progresses in low-power design. The most effective technique is adiabatic logic circuit design in energy-efficient hardware. This paper presents two adiabatic approaches for the design of low power circuits, modified positive feedback adiabatic logic (modified PFAL) and the other is direct current diode based positive feedback adiabatic logic (DC-DB PFAL). Logic gates are the preliminary components in any digital circuit design. By improving the performance of basic gates, one can improvise the whole system performance. In this paper proposed circuit design of the low power architecture of OR/NOR, AND/NAND, and XOR/XNOR gates are presented using the said approaches and their results are analyzed for powerdissipation, delay, power-delay-product and rise time and compared with the other adiabatic techniques along with the conventional complementary metal oxide semiconductor (CMOS) designs reported in the literature. It has been found that the designs with DC-DB PFAL technique outperform with the percentage improvement of 65% for NOR gate and 7% for NAND gate and 34% for XNOR gate over the modified PFAL techniques at 10 MHz respectively.
How you define the “root” cause will depend on your objectives and motives in undertaking the investigation
(Do a demonstration dropping a ball… ask what the root cause is…)
History, development, different “schools of thought”
For example…
Why did the ball fall?
http://www.national.com/analog/quality/8d
How many could have the problem but don’t
Suspensions – what portion of the population is failing? At what rate?
What is acceptable? What is the threshhold?
Use of statistics in medical, pharmaceutical fields
Have the data…
One of the primary roles of the Reliability Engineer is to see that the correct data is collected
Collect data on non-failures
You aren’t the expert…
On which piece of equipment at your facility are you the most knowledgeable person in the plant?
If you are the most knowledgeable person, what don’t you know?
You are not the expert…
For What % RCFA’s you are likely to be involved in, are you the single greatest repository of knowledge about possible causes and effects?
Even then… There is critical information you don’t know or have
The “apocryphal” story of the great engineer who “just saw” an obscure answer that noone else saw… that is a rare event. That is why it makes such a great story.
Assume that you will have some responsibility to do RCFA’s within your organization
Things that illustrate some of the basic principles… one or two key take-aways
Some (not all) things that they might have occasion to deal with
Vibration wherever possible
Brake temperature constrains operations
Excessive temperature
Department of Defense Inspector General Auditing Report 99-193, C-17 Landing Gear Durability and Parts Support, June 24, 1999
Expensive, failed attempts to solve the problem already
“Failure rate…”
References:
References:
C:\Documents and Settings\GCottle\My Documents\0\Archived\Vol1041\0\Automation Group R&M\2004\BRM\Background history and reference.zip\ETC_timeline-International Plugs and Fittings History.doc
C:\Documents and Settings\GCottle\My Documents\0\Archived\Vol1041\0\Automation Group R&M\2004\BRM\20040607_HEUI_Warranty_Review.zip
Ref
C:\Documents and Settings\GCottle\My Documents\0\Archived\Vol1041\0\Automation Group R&M\2004\BRM\20041116_Sleuthing.zip\PRES.2004.11.15.LB TO Cottle T. Hanks Talking Points
Ref:
20050114 R&M Overview
What to do with the contractor’s conclusion…
Don’t discard it. They know more about the design than most of us.
Can you accept it? (Obviously not…)
What to do with the contractor’s conclusion…
Don’t discard it. They know more about the design than most of us.
Can you accept it? (Obviously not…)