This TQM article, is a continuation from Part 5a published on [June 01, 2006 08:10:51 pm]. I will share about problem or difficulties faced by the team when they use the tools in the IMPROVE PHASE. Lets see how we can handle problem or difficulties with Control lot and testing and Pilot the action / solution tools in the D.A.I.C. methodology for Improvement.
Just to recap, tools used in the IMPROVE Phase are listed below. In this article, I will cover the tools in bold:
Brainstorming of action / solution | Selection Grid | Benchmarking | Cost-Benefit Analysis| Control lot and testing | Pilot the action / solution | Force-Field Analysis | Prevention Planner
Problem with Control Lot and Testing
It is quite a challenge to use this tool not the tool itself but the planning go with it when need to run a control lot. First of all, the team need to consider several issues namely; Size of the control lot, duration of run, what parameter need to confirm, who will be involved, when to run it? Which shift to run it, and how is data to be collected. Due to lack of experience, the team struggle with it
I had a case where the team needs to confirm 4 process parameters. When the control lot is in progress, team members set the 4 parameters at the same time then data is collected. At the end of the run, data collected are not useful to make any correlation as they did not provide any pattern.
How to Overcome Control Lot and Testing Problem
Team need to understand the inter-relationship between each of the four parameters and how it influences the coating thickness. By requirement, the team needs to run four control lots for each of the parameter as a variable separately. In another word, the team needs to adjust one parameter setting with the rest the three locked. The idea is to see the effect of one parameter to the thickness by turn.
Problem with Pilot the action / solution
During the case of coating thickness, the team has confirmed the various setting after the control lot run. During the pilot run, team run into trouble even though all the four parameter wee set according to the new requirements. Production supervisor may over react and set the four parameters back to the old setting. It did not help either. As a result, reject for coating thickness increased dramatically.
How to Overcome Pilot the action / solution Problem
When conducting the pilot run, team member must be around to work with the production supervisor to give him confidence about the new settings. When things might go wrong, team members need to verify other process parameters before any change to the control lot parameter are changed. Team members need to explain to the production supervisor that process parameters are sensitive to influence the outcome of the product. Therefore, all process parameters must be set in accordance to standards.
In summary, to minimise problem arising from changes to proicess parameters, communication play an important role. A briefing to the objective of the pilot would help to munimise surprise not only to the production staffs, also to the team members. Now that the solution seem working alright, the team should move into the the CONTROL PHASE which will be my next article.
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About the Author: LM Foong:
The author provides consulting services specializing in TQM Implementations in manufacturing and service sector. He provides facilitation workshops and hands-on application in Cost Reduction and Productivity Improvement projects. He publishes TQM articles, ebooks, case studies, trainer manual and presentation slides. Please click To View Free TQM articles or Please Visit my Web Site for other TQM related matters.
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