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

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