(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)+(+)+(+)+(+)+(+)
(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)+(+)+(+)+(+)+(+)
(+)+(+)
(+)+(+) S.M.I.L.E(sm)
(+)+(+)
(+)+(+) Setup Minimization Improves Line Efficiency
(+)+(+)
(+)+(+) The Lean Changeover e-letter
(+)+(+)
(+)+(+) Published monthly by Changeover.com
(+)+(+)
(+)+(+) Written by John R Henry, CPP
(+)+(+)
(+)+(+)
(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)+(+)+(+)+(+)+(+)
(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)(+)+(+)+(+)+(+)+(+)+(+)

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### APRIL 2007
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=============================================================
SOME THOUGHTS ON...
ISHEKAWA CHARTS

Last month I talked about effective troubleshooting. This month I want
to talk about a helpful tool.

Shamless plug: If you are interested in information about having me
present my Effective Troubleshooting workshop in your plant, click
here www.changeover.com/trouble.pdf, e-mail me at
johnhenry@... or call me at 787-550-9650

The Ishekawa Chart is sometimes called a Fishbone chart or diagram. It
is a simple yet powerful tool for identifying the potential sources of
problems. One form has a horizontal line naming the problem at the
right. Four lines branch off at 45 degree angles with major groups of
possible causes of the problem. These are labeled "Machine", "Method",
"Man" and "Material".

Each of the angled lines has horizontal lines running to the left or
right detailing possible causes.

As an example, let us consider a rotary capper such as a Consolidated
or Pneumatic Scale. Let us assume that the problem is that caps are
not being tightened consistently. The major horizontal line would be
labeled "Inconsistent torque".

Branching off the horizontal at about a 45 degree angle would be
category lines or "bones". There should be at least 4 labeled Man,
Machine, Materials and Method. In some cases there might be more than
four, say for environment.

A series of horizontal lines then comes off each of the bones. All
possible causes are listed on those lines.

All possible causes of the inconsistent torque would be listed in one
of the four categories.

The "Materials" bone will list such potential causes related to
materials or components. Examples could include:
-Deformed bottles
-Oversized caps
-Excess mold release on the bottle or other causes
-Poor quality glue

"Man" related issues include anything related to or caused by
personnel operating the machine. This can include
-Improper setup or cleaning prior to the production run
-Failure to keep the machine clean during the run
-Improper technique in checking the cap torque. In other words, the
torque might be appear to be inconsistent but the problem is that the
operator is not checking it properly.

"Machine" can cover a wide range. It is important to remember that it
is not only the capper itself but includes anciliary equipment as
well. Machine problems include:

-Damaged or worn parts
-Vibration
-Overheating
-Damaged toque tester. The torque may be OK but the tester may be
indicating a problem.

"Method" includes all problems related to the way in which the capper
is operated:

-Speed may not be properly set. This could be a setup problem or it
could be a problem of the operator varying the speed during operation.
-The speed of other machines up and downstream may not be properly set
causing problems with the capper
-Over or underfilling the cap hopper can sometimes cause problems.

The above is meant to be illustrative not definitive. Those of you
will cappers will probably identify some things I have left out or
never experienced some of the things I mentioned. The Ishekawa chart
needs to be tailored to each piece of equipment as well as each major
problem.

There is also an issue of where to catagorize things. Is improper
setup an "man" or a "methods" item? It could be classed as either or
both. It could even be categorized as a "machine" problem if the
machine does not readily lend itself to repeatable setups.

The best time to develop an Ishekawa chart is either before or after a
problem occurs. A way to approach this is to develop a blank chart
template. A series of templates would be prepared for each machine. To
continue with our capper example, a series of blank charts would be
prepared with one each for "Inconsistent Torque", "Bottle Jam",
"Bottle breakage" and other major problems.

Some of the items could be filled in ahead of time simply by talking
with the mechanics and operators. To the extent that this can be done,
great. The charts should also be viewed as a work in progress. That
is, as new problems arise, they should be added to the charts. The
charts should be kept in close proximity to the machine to allow ready
access when troubleshooting.

In my experience, a lot of time is spent reinventing the wheel in
troubleshooting. A tool like the Ishekawa chart provides a means of
capturing the information and providing a starting point the next time
a similar problem occurs.

For an example of an Ishekawa chart that I use in my workshops, see
www.changeover.com/chart.jpg




TIP OF THE MONTH...
OIL ANALYSIS

Oil analysis is a useful tool for predictive maintenance. The oil from
a transmission, or crankcase can tell a lot about what the machine has
been doing. Typical information from an oil analysis includes metallic
& non-metallic particles, breakdown of lubricating properties,
dielectric breakdown, oxidation and fuel contamination.

It used to be that samples needed to be collected and sent to a
laboratory for analysis. In recent years more portable systems have
become available. One such system is the SKF TMEH1 OilCheck. This is
small, handheld system that allows oil analysis on the spot. It is
cheap enough that any maintenance shop can afford on.

It is available here
http://www.reliabilitydirectstore.com/Oil_Analysis_s/184.htm

Best,

John R Henry CPP

www.changeover.com
787-550-9650