Floor Tape Store

Monday, November 26, 2012

The Benefits of PFMEA in Preventing Failures


FMEA is a systematic analysis of potential failure modes aimed at preventing failures. This is intended to be a preventative action process carried out before implementing new or changes in products or processes. An effective FMEA identifies corrective actions required to prevent failures from reaching the customer and to assure the highest possible yield, quality and reliability.

What Is An FMEA?

  • A tool used to evaluate potential failure modes and their causes.
  • Prioritizes Potential Failures according to their Risk and drives actions to eliminate or reduce their likelihood of occurrence.
  • Provides a discipline/methodology for documenting this analysis for future use and continuous process improvement.
PROCESS FMEA:
Analytical technique used by manufacturing / engineering team as a means to assure that, to the extent possible, potential failure modes and their associated causes or mechanisms have been considered and addressed. This systematic approach parallels and formalizes the mental discipline that an engineer goes through in any manufacturing planning process.

Process FMEA Benefits
  • Identifies potential “manufacturing or assembly” process failure modes.
  • Identifies potential “product related” process failure modes.
  • Assesses the potential customer effects of the failures.
  • Identifies operator safety concerns.
  • Identifies process variables on which to focus controls for occurrence reduction / elimination or detection of the failure conditions.
  • Develops a ranked list of potential failure modes ranked according to their affect on the customer, (both external & internal), thus establishing a priority system for corrective actions.
  • Feeds information on design changes required and manufacturing feasibility back to the design community.
 Process FMEA Outputs
  • A list of potential process failure modes.
  • A list of processes or process actions to:
    • reduce Severity
    • eliminate the Causes of product failure modes
    • reduce their rate of Occurrence
    • improve product defect detection if process capability cannot be improved.
  • A list of critical characteristics and special controls to be entered on a Manufacturing Control Plan.
Roles and Responsibilities:
FMEA Facilitators:
  • Experienced in methodology, guides PFMEA
  • Does all the grunt work, finds and gathers all the data
Team Members:
  • Subject matter experts
  • Gives opinions and estimates, data if available
  • Guides facilitator to source of data if not immediately available
  • Verifies what Facilitator writes down
 Why do PFMEA? (WIIFM = what's in it for me?)
  • Increases the probability that potential failure modes and their effects have been considered in a cross-functional team environment.
  • Aids in the planning or development of processes and testing 
  • Ranks potential failure modes according to the effect on the customer, hence prioritizes improvements and controls for best use of limited resources
  • Sets priorities for manufacturing controls 
  • Proactive concurrent engineering & manufacturing approach
Process FMEA is a process design verification activity that can help avoid a minimum of 80% of process design problems before the process design is finalized.



Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Friday, November 23, 2012

Lean Quote: Thanksgiving, More than Just Words

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.

"As we express our gratitude, we must never forget that the highest appreciation is not to utter words, but to live by them." — John Fitzgerald Kennedy

Thanksgiving Day has evolved over the years as an important holiday. It is not just about feasting and merrymaking. The tradition of Thanksgiving dinner teaches us to appreciate the finer things in life. It is about showing one's gratitude for the blessings that we are showered with. In all the hustle and bustle of getting ready for Thanksgiving, take a moment to focus on what being thankful is all about. 

Being thankful for what we already have is probably the most powerful tool of positive thinking. The ability to notice what we already have and to consider ourselves blessed with it truly unlocks the door to abundance and to feeling good.

I wanted to take this time to thank all of you for reading, following, and supporting A Lean Journey Blog. You make sharing my thoughts more rewarding than I would have imagined.

As we gather to celebrate Thanksgiving, may we vow to live not just this day but every day with a grateful heart and to use our blessings to bless others.



Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Thursday, November 22, 2012

Happy Thanksgiving to You!



Thanksgiving Friends

Thanksgiving is a time
For reviewing what we treasure,
The people we hold dear,
Who give us so much pleasure.

Without you as my friend,
Life would be a bore;
Having you in my life
Is what I’m thankful for.

By Joanna Fuchs

I would be remiss if I did not take time to thank all of you for reading, following, and supporting A Lean Journey Blog. I am deeply grateful for the opportunity to share my journey in Lean with you. You make sharing my thoughts more rewarding than I would have imagined.   



Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Wednesday, November 21, 2012

Paul Akers Shares Tips for Morning Meetings

What's the point of the morning meeting? Paul Akers says it is about building a team. You can not build a team when the leader is talking. The leader must ask employees questions so they talk. When employees talk you are building a team.  What do you ask? Ask them "what bugs you?" Problems are not the employees fault. Management is to blame.

Paul shares a number of tips about establishing your own morning meeting.



Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Tuesday, November 20, 2012

Daily Lean Tips Edition #39

For my Facebook fans you already know about this great feature. But for those of you that are not connected to A Lean Journey on Facebook or Twitter I post daily a feature I call Lean Tips.  It is meant to be advice, things I learned from experience, and some knowledge tidbits about Lean to help you along your journey.  Another great reason to like A Lean Journey on Facebook.

Here is the next addition of tips from the Facebook page:

Lean Tip #571 – Identify and remove root causes to permanently fix problems.

The root cause is the fundamental, underlying reason for a problem. The root cause is what causes a problem to happen repeatedly. If you do not identify the root cause, you are just putting a bandage on the problem. It will probably happen again. When you remove the cause, you have fixed it permanently.

Lean Tip #572 – Monitor your improvement results to see your target was achieved, not just whether there was a change.

If you didn’t accomplish what you had hoped, three reasons are possible. Your plan may have been poorly executed. You may have developed a poor solution. Or, you may have attacked the wrong cause. Try again if necessary.

Lean Tip #573 – Data collection and analysis tools are critical for monitoring improvement.

Did you accomplish your objectives? When you review the results, ask whether your targets have been achieved. Process analysis and monitoring tools are important for determining whether the overall project goals were met.

Lean Tip #574 – If your solution worked, standardize to lock in the improvement.

Introduce the solution to everyone affected. Make sure whatever changes have been made become routine. Prevent any slipping back into the same old problems. Consider all elements of the new process: people methods, machines, materials, and measurements. Have they all been standardized?

Lean Tip #575- There are several aspects to standardizing an improvement process.

First, “new and improved” won’t do much good unless it is used consistently throughout the organization. Plan to expand your test solution to everywhere it appears. Second, everyone involved in the new proves must know what to do. Formal and informal training is essential to spread a new process throughout the organization. Third, it is critical to identify who owns the improved process, including responsibility for continued tracking of measurement.

Lean Tip #576 - Enable Employees by Setting Clear Goals.

People make more progress when leaders are clear about the link between what they do and what matters to the organization. And successful teams are those that have clear goals, and where people know how their work affects those goals. Help your people gain line of- sight visibility from their work to the team’s goals.

Lean Tip #577 – Help employees break projects, goals, and work assignments into small victories.

Small victories tap into motivation. Achieving is fueled by making small amounts of progress, such as accomplishing a task or solving a problem. Help those that work with you jump into an achievement cycle and experience the benefits and rewards of moving through all five steps.

Lean Tip #578 - Teach people how to manage time and energy wisely.

Coach employees to fully engage in the task at hand, focus on the important rather than the urgent, avoid distractions, and create balance and renewal in the achievement of the goal. Help them learn to say no to urgent requests or terrific ideas that aren’t aligned with the important work of the team.

Lean Tip #579 – Enable employees by committing resources and removing roadblocks.

Enable people to move forward in their work by committing appropriate resources, removing obstacles, helping them work across boundaries, and aligning processes, structure, and systems.

Lean Tip #580 - Help employees engage others.

Encourage those you work with to reach out and engage others with similar goals. Remind them that goals can be created independently, but achieving them almost always requires help and support from others.

Lean Tip #581 - Employees need to be able to trust their managers and company leadership.

Clear communication is a key element of trust. To build trust, monitor how and what you communicate to people around you. Be clear and direct. Manage expectations. Be truthful and as transparent as possible to avoid guesses and assumptions and to prevent rumors and unfounded fears from spreading. In organizations under stress, sometimes it is difficult for leadership to be completely forthcoming. Few people expect everything to be perfect all the time, but uncertainty breeds discontent. Tell employees as much as possible as early as possible, even if it is bad news.

Lean Tip #582 – Leaders Need To Create Connections For Employees

People want to have meaning in all aspects of their lives. If they do not feel the importance of what they do, they disconnect. Therefore, it is important to highlight the connections between things and people. Help employees see the “big picture” of how their role and objectives fit into the organization’s objectives. Encourage others to look at how their actions and performance affect others.

Lean Tip #583 – If You Want Engaged Employees Motivate Them with Appreciation.

Recognition is an important part of motivation and engagement, and it can be as simple as genuine appreciation. Praise where warranted and give credit where credit is due. The best recognition is immediate, specific, and personal. Let the person know specifically what you appreciate about her or what she did, and do so in a way that the individual will appreciate (some people like public praise, others prefer a one-to-one chat).

Lean Tip #584 – Strong Leaders Motivate Others to Be the Best They Can Be

Motivation is our desire or willingness to do something. An organization where people are willing and able to work toward a common goal is stronger than one where people are badgered or threatened or generally reluctant. Leaders with higher degrees of emotional intelligence tend to get better results through inspiration, persuasion, empathy, and integrity. Use your listening, persuasion, and influence skills to inspire and motivate people to work toward a common goal.

Lean Tip #585 - Support Your Employees by Developing Their Growth

There is nothing more demotivating than feeling you’re in a dead-end job. Talk to employees about what direction they’d like to see their career path take, and help them identify opportunities for personal and professional development that will help them achieve those goals. Share with them ideas they can use for their own career management within the organization. Move past any fear you may have of your employees leaving – by caring about their growth and aspirations, you will probably get a more productive, loyal, and longer-term team member than if you don’t have these conversations.


Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Monday, November 19, 2012

Facts Speak For Themselves


The general causes of troubles in factories arise from wrong knowledge and incorrect operations. To discern what is wrong and what is incorrect we have to launch into a fact finding process.

“The Facts.”

An overused expression.
Everybody assumes he knows, but no one actually knows.
One might be reminded of a story of the blind men touching an elephant and each reporting different description of what the elephant is.
One touches the trunk and talks only that, another touches the tail and describes the elephant as such.
Each believes his experience to be correct.
People often tell the stories from others as if they were their own experiences.

Discussions alone cannot eliminate troubles.
Words cannot always describe facts.
What is white may turn out as black.
Discussions cannot settle whether it is white or black.

“Let facts speak for themselves.”

With a humble attitude, carefully check things one by one.
At any rate what we are dealing with is a difficult thing.
It has an infinite number of features.
We must be aware that our knowledge and experience are finite, and always imperfect.
This recognition will make the facts appear.

A person who has engaged in a job for a long time is the one we call experienced.
As experienced person has a great deal of knowledge about that job.
These are correct knowledge and incorrect knowledge.
The problem is that he doesn’t know which is correct and which is wrong.
A true expert is the experienced person who is always furnishing his knowledge with facts, reflecting on that knowledge and making corrections.
Unfortunately, all persons with experience are not necessarily be true experts.
They can become encumbrances who bear superstitions.

We have to work diligently to find true knowledge.
It is just like in climbing a mountain road, you have to climb one step at a time.
After you’ve continued the climb for some time, you’ll suddenly realize how far you are above the starting point.



Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Friday, November 16, 2012

Lean Quote: Four Attributes of an Effective Performance Measurement System

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.

"What gets measured gets done. Make sure you are measuring the right things!" — Peter Drucker

An effective measurement system is one of the most powerful tools for change. In a perfect world, a measurement system will actively promote performance improvement by measuring what matters; providing corrective feedback and positive reinforcement to enthusiastic people who enjoy being measured and take improvement on as a challenge.

An effective performance measurement system should have the following four attributes:

First key of a successful measurement system is Context. Effective measurement can only occur in a positive, supportive context. This is the culture that surrounds the measurement - informational or punishment, process not person. The attitude of the boss. An unfavorable measure is an opportunity not a threat. We want to surface issues, not suppress them.

The second key for a successful measurement system is Focus. Measure the right thing. Be aware of measuring too much. Derive many of the measures from participative policy deployment, not sucked out of the air.

The third key for a successful measurement system is Integration. There must be an integrated system for measurement. Maybe a balanced scorecard or policy deployment, although better in a Lean context would create flow, maintain flow, and organize flow. In any case measures need to be aligned, balanced, and adaptive.

The fourth key for a successful measurement system is Interactivity. Measures need to be acted on in real time. Two-way interaction. Actually setting up the measures is only a small part - how they are used and reviewed is at least as important. Perhaps a daily meeting around the communications board. This is social process, not a technical process.

Good systems need good people. There is no sense in examining a process unless at the same time you examine the people who govern the process. Improvement does not take place on paper. Improvement happens when people employ enthusiasm, dedication, commitment, leadership and morale in their daily routine. A good system on paper is a healthy beginning but if you want results you need to follow up a paper system with a people system.


Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare