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Old procedure grinding and new etching process with sop

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8D APPLICATION
- THE TOOL CRASH PROBLEM -

Typical 5 Why• Tool crashed into part

Why?: Program reengaged without raising tool
to clear part
Why?: operator inattention

1) Team
2) Problem Description
3) Containment Action(s)
4) Root Cause(s)
5) Chosen Permanent Corrective Action(s) 6) Implemented Permanent Corrective Actions 7) Actions to Prevent Recurrence
8) Congratulate your team

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2) For remaining 5 parts in lot, program a tool change midway through the cycle where tool appropriately clears part before reengaging.

3) For similar parts, assess risk of similar problem. Program tool change based on risk assessment.

Tool material wear rate too fast
Tool material selection not best
Tool crashes into part Program caused tool to crash into part
Re-engaging a program –
will resume it is where interrupted
Program not set up to allow
controlled tool change
Program 10

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3) Training checklists modified to required new employee training on the procedures and refresher training of all impacted employees on a bi-annual basis.

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Annual Conference H.E. Romeijn, A. Schaefer, R. Thomas, eds

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Eight-Step Improvement of a Materials Engineering
Laboratory Class

Nihal Nethada & Hung-da Wan
Mechanical Engineering Department and
Center for Advanced Manufacturing and Lean Systems The University of Texas at San Antonio

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Pick Chart – technique for prioritization Easy 1
Implement
of alternatives based on impact/ Hard 3
effectiveness in solving the problem

versus ease or cost of implementation.

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Step 8: Standardize successful process

• SOP for grinding are created
• Suggestion provided with the need of supplies and changes to operating procedures.

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End of presentation
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