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PS I. 365. Problem Solving I nnovator. The name that says it all:. PS I. Problem Solving I nnovator. 365. will exponentially improve the effectiveness of any Organizations. P reventive A ction C orrective A ction I mprovement A ction. PS I. 365. will …. Increase Efficiency.

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PS I

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  1. PSI 365 Problem Solving Innovator

  2. The name that says it all: PSI Problem Solving Innovator 365 will exponentially improve the effectiveness of any Organizations PreventiveAction CorrectiveAction ImprovementAction

  3. PSI 365 will … Increase Efficiency ReduceMan Hours Improve Effectiveness

  4. incorporate the methodology of 8DTeam Orientated Problem Solving with … PSI 365 5Why Analysis and supported by automatic generation of Failure Mode & Effects Analysis Cause & Effect Diagrams including Causes, Preventive Action and Detection Controls, SOD& RPN Calculation; Risk Reduction & Improvement Actions.and supported by: • Brainstorming; 5M, • Is/Is Not Analysis; • Comparative Analysis; • Paired Comparison, • Affinity Diagram; • Pareto Analysis, • Risk Analysis, • Force Field Analysis, • Cost Benefit Analysis, • Implementation Plan • Lessons Learned Database • as well as • Automatic & Comprehensive 8D Status Reporting.

  5. 5 WHYS 5WHY Problem Solving Methodology is used World Wide Lets take a look at how it works

  6. PROBLEM Brainstorming 5M Approach 1st WHY Cause of 1st WHY 2nd WHY Cause of 2nd WHY 3rd WHY Cause of 3rd WHY 4th WHY Problem Torch Bulb Cause of 3rd WHY is Dim 5th WHY Root Cause

  7. Brainstorming stimulates new thinking and creates the maximum number of ideas in the minimum amount of time. It’s a technique which aims at encouraging all team membersto contribute all the ideas they believe could be affecting the problem. Batteries Flat Bulb Damage Corrosion Reflector Environment Earth Damaged Face Value Contact Case Insulation Liquid damage Glass/ Lens Drawing Current

  8. A Problem Solving Team identified 5 main Functions of the Torch that could have Failed The Team then Prioritizes the probability of these Functions hosting the Root Cause of a Dim Bulb. With some basic observations, the Team was able to determine that the Bulb was getting Insufficient Electrical Current and therefore identified the … 1st Why (Function of Torch) is identified as "Insufficient Current” but could also have been …

  9. The Team identified 4 main Requirements of the Function Current 1 3 4 2 The Team then Prioritizes the probability of these Requirements hosting the Root Cause of a Dim Bulb With some basic observations, the Team was able to determine that the Bulb was getting Insufficient Electrical Current and therefore identified the … 2nd Why (Requirements of Current) is identified as “Poor Contact” but could also have been

  10. Diagrams and Images may be useful when trying to understand Possible Cause & Effects 11 12 7 9 2 3 4 6 1 8 10 5

  11. The Team identified 3 Failure Modesof the Requirement Contact • The Effect of the Failure Mode “Insufficient Current” • can be matched to the initial problem “Corroded Contact” 3rd Why (Failure Mode of Contact) but could also have been is identified as “Corroded Contact”

  12. The Team identified 2 Root causesfor each Failure Mode • 4th Why (Root Cause of Corroded Contact) • is identified as “Environmental Moisture” • but could also have been “Battery Leakage”

  13. 5th Why The Prevention Controlcan be identified against the Root Cause What was supposed to Prevent the mistake happening? • 5th Why The Detection Control can be identified against the Failure Mode • Why did we let the Mistake become a Problem? (a Basic Poka Yoke Principle) • The Weakness of the Detection Control can also be identified

  14. The Prevention Control & The Detection Control can now be analyzed and any Potential Improvements (and subsequent Risk Reduction) determined .

  15. The Recommended Prevention Control& The Detection Control Improvements can now be reflected under Recommended Improvements in the FMEA.

  16. FMEA – Failure Mode and Effect Analysis • FMEA & Cause and Effect Diagrams • Automatically update accordingly to the 1st Why stage through to the 2nd, 3rd & 4th Why

  17. Edit / Add as required the • 3rd Why Failure Effect • 4th Why Root Failure cause • 5th Why Detection Controls • 5th Why Detection Weakness • The Severity of the Failure Mode; • The Occurrence of the Root Cause and • The Effectiveness of the Detection can be evaluated • and entered in order to generate and overall Risk ( RPN -Risk Priority Number)

  18. PSI365 automatically builds Cause & Effect Diagrams. Cause & Effect Diagrams can be analyzed from the 1st Why stage through to the 2nd 3rd & 4th Why stages Cause & Effect - Fishbone

  19. PSI365 summarizes all Functions, Requirementsand Failure Modes • together with • Root Causes • and current • Prevention Actions • Detection Controls

  20. Solutions / Short List PSI 365 will prioritize the top 3 RPN Values per Function. The Team can select those Recommended Improvements which will have an impact on the stated Problem, and push these through for further evaluation in the Force Field Analysis.

  21. Force Field Analysis Selected Recommended Actions are automatically pulled through to an optional Force Field Analysis for evaluation and justification.

  22. PSI365 provides for the Optional use of a Cost Benefit Analysis. Cost Benefit Analysis should be assessed against the Recommended Improvementsas a motivational and decision makingtool for approving the Recommended Improvements.

  23. PSI365will now summarize The 1st Why Function Raw Material The 2nd Why Requirement Thread Adaptor Casing The 3rd Why Failure Mode Inclusions in thread Adaptor The 4th WhyRoot Cause Cutting Tool Damaged The 5th Why Prevention Tool Monitoring &Detection Inspection Recommended Improvement Prevention Increase Inspection of Cutting Tool Damage Detection Final Inspection (Sampling) Approved Actual Improvements Prevention Increase Inspection from First / Last Off to every 10 Products Detection Amend Final Inspection Instructions to include Thread Damage This will be repeated for all Improvement Actions that were Approved

  24. PSI365provide for the Optional use of an Implementation Plan. Relevant Data from Approved Implementation Actions, including the Actual Change, and Due Dates are automatically populated. The optional use of Time per Task + Elapsed Time indicates the efficiency of the Implementation Plan, whilst the Date Completed permits monitoring of the Real Time Progress.

  25. Prevention/ Lessons Learned What actions have been taken to ensure that the Root Cause does not re-occur? Can the Potential Causes / Solutionsbe applied elsewhere in the Organization? Potential Improvements Comment in the text box given with any proposed change methodsand or Justificationsto the problem and its prevention Process System Improvements Now add in anySystem Weaknesses and Improvements that have been identified and acknowledged within the PSI

  26. 8D Report

  27. A certificate of Recognition is awarded to each staff member of which assisted in the PSI 8D’s as a Recognition and Appreciation for the work, time and effort placed towards the problem solution.

  28. Thank you for viewing this presentation, Please do not hesitate to contact us: National: Tel:   0861 101 708 Fax: 0861 100 288 International: Tel:   (+27) 43 748 1925 Fax: (+27) 43 748 6656 Email: info@hoquality.com Website: www.hoquality.com

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