WCM requires all decisions to be made based on objective measured data and its analysis. Therefore, all the traditional data analysis tools such as scatter diagrams, histograms and checklists are used. Thus, from literature survey it is inferred that it is not possible to use the specific single tool to achieve world-class performance and address all the manufacturing components. It is inferred that to address all the components of the manufacturing system the following tools are necessary (see Table 1.2):
|
Main Tools |
Description |
|---|---|
|
5 G |
It is a methodology for the description and the analysis of a loss phenomenon (defects, failures malfunctions...). It based on the facts and the use of the 5 senses |
|
4M or 5M |
It is used by the list of possible factors (causes, sub-causes) that give rise to the phenomenon. For the 4M the causes are
grouped into 4 categories: Methods; Materials; Machines; Mans. |
|
5 S |
It is used to achieve excellence through improvement of the workplace in terms of order, organization and cleanliness. The technique is based on: Seiri (separate and order); Seiton (arrange and organize); Seiso (clean); Seiketsu (standardized); Shitsuke (maintaining and improving). |
|
5W + 1H |
It is used to ensure a complete analysis of a problem on all its fundamental aspects. The questions corresponding to the 5 W and 1 H are: Who? What? Why? Where? When? How? |
|
5 Whys |
It is used to analyze the causes of a problem through a consecutive series of questions. It is applied in failures analysis, analysis of sporadic anomalies, analysis of chronic losses arising from specific causes. |
|
AM Tag |
It is a sheet which, suitably completed, is applied on the machine, in order to report any anomaly detected. |
|
WO Tag |
It is a sheet which, suitably completed, is used in order to report any anomaly detected for Workplace Organization |
|
PM Tag |
It is a sheet which, suitably completed, is used in order to report any anomaly detected for Professional Maintenance. |
|
Heinrich Pyramid |
It is used for classifying the events that have an impact on safety such as fatalities, serious, minor, medications, near-accidents, accidents, dangerous conditions and unsafe practices over time. |
|
SAF Tag |
It is a sheet which, suitably completed, is used in order to report any anomaly detected for Safety. |
|
Equipment ABC Prioritization |
It is used to classify plants according their priorities of intervention in case of failure. |
|
Cleaning cycles |
Are used for activities on Autonomous Maintenance, Workplace Organization and Professional Maintenance. |
|
Inspection cycles |
Are used for activities on Autonomous Maintenance, Workplace Organization and Professional Maintenance. |
|
Maintenance cycles |
Are used for activities on Autonomous Maintenance and Professional Maintenance. |
|
Control cycles |
Are used for activities on Autonomous Maintenance, Workplace Organization and Professional Maintenance. |
|
FMEA-Failure Mode and Effect Analysis |
It is used to prevent the potential failure modes. |
|
Kanban |
It is a tag used for programming and production scheduling. |
|
Kaizen (Quick, Standard, Major, Advanced) |
It is a daily process, the purpose of which goes beyond simple productivity improvement. It is also a process that, when done correctly, humanizes the workplace, eliminates overly hard work. |
|
Two Videocamera Method |
It is used to perform the video recording of the transactions in order to optimize them. |
|
MURI Analysis |
Ergonomic analysis of workstations. |
|
MURA Analysis |
Analysis of irregular operations. |
|
MUDA Analysis |
Analysis of losses. |
|
Spaghetti Chart |
It is a graphical used to detail the actual physical flow and distances involved in a work process. |
|
Golden Zone & Strike zone Analysis |
Analysis of work operations in the area that favors the handling in order to minimize movement to reduce fatigue. |
|
OPL (One Point Lesson) |
It is a technique that allows a simple and effective focus in a short time on the object of the training. |
|
SOP (Standard Operation Procedure) |
Standard procedure for work. |
|
JES (Job Elementary Sheet) |
Sheet of elementary education. |
|
Visual Aid |
It is a set of signals that facilitates the work and communication within the company. |
|
Poka Yoke |
It is a prevention technique in order to avoid possible human errors in performance of any productive activity. |
|
TWTTP (The way to teach people) |
It is an interview in 4 questions to test the level of training on the operation to be performed. |
|
HERCA (Human Error Root Cause Analysis) |
It is a technique for the investigation of events of interest, in particular accidents, which examines what happened researching why it happened. |
|
RJA (Reconditional Judgment Action Analysis) |
Analysis of judgment, recognition and action phases at work. |
|
5Q 0D (Five Questions to Zero Defects) |
Analysis of the process or of the equipment (machine) through five questions to have zero defect. |
|
DOE |
It is a techniques enables designers to determine simultaneously the individual and interactive effects of many factors that could affect the output results in any design. |
|
ANOVA |
It is a collection of statistical models, and their associated procedures, in which the observed variance in a particular variable is partitioned into components attributable to different sources of variation. |
|
PPA (Processing Point Analysis) |
It is used for restore, maintain and improve operational standards of work by ensuring zero defects. |
|
QA Matrix (Matrix Quality Assurance) |
It is a set of matrices which shows the correlations between the anomalies of the product and the phases of the production system. |
|
QM Matrix (Matrix Maintenance Quality) |
It is a tool used to define and maintain the operating conditions of the machines which ensure performance of the desired quality. |
|
QA Network quality assurance network |
It is used to ensure the quality of the process by eliminating rework. |
|
QuOA quality operation analysis |
Preventive analysis of the work steps to ensure the quality. |
|
SMED (Single Minute Exchange of Die) |
It is a set of techniques to perform operations of development, set-up, with a duration < 10 minutes. |
|
Rhythmic operation analysis |
Analysis of the dispersion during the work cycle. |
|
Motion Economic Method |
Analysis used to evaluate the efficiency of movement and optimize them. |
|
Value Stream Map |
It allows to highlight the waste of a process business, helping to represent the current flow of materials and information that, in relation to a specific product, through the value stream between customer and suppliers. |
|
Material Matrix |
Classification of materials according to tree families A – B - C and subgroups. |
|
X Matrix |
It is a tool for quality improvement, which allows compare two pairs of lists of items to highlight the correlations between a list, and the two adjacent lists. X matrix to relate defect mode, phenomenon, equipment section and quality components. |
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