Step 01 Stating the Problem

1.1 Current Status 33 Accidents in the first four Months

1.2 Standard 0 Accidents

1.3 Gap 33
1.4 Ultimate Goal To create a safe envrinments by having 0 accidents & so to imrpove moral of the em
1.5 Time Line January 1st to April 30th
1.6 Team Nilushini & Naduni

STEP 02 Problem Break Down

Accidents Count
Burn 0
Cut 12
Needle prick 20
Other 1
Total 33

Break Down of the Needle pricks

January February
Operation Finger Count Operation
A Zigzag
SEC 01 B Ring 1 Zigzag
A 0 0 0 0
SEC 02 B Zigzag Index 2 …../ Bartag
A Single NeedleThumb 1 Zigzag
SEC 03
B Bartag / ….. Thumb 2 Bartag
Zigzag
A 0 0 0 0
SEC 04 B 0 0 0 0

Column1 Column2 Zigzag Count Single Needle Bartag Over Lock

SEC 01 A 2 0 0 0
B 3 1 0 0
SEC 02 A 0 0 0 0
B 2 0 0 0
 SEC 03 A 2 1 1 0
A 0 0 0 1
B 0 0 1 1
B 1 0 0 0
SEC 04 A 0 0 0 1
B 0 0 0 0
10 2 2 3
% 59

Finger - Finger - Zigzag -

Zigzag Count Finger type
SEC 01 A Middle 2 Middle
B Middle 1 Index
Index 2 Thumb
SEC 02 A 0
B Index 2
SEC 03 A Index 1
Thumb 1
B Thumb 1
SEC 04 A 0
B 0
10

STEP 02 Point Of Occurance

Panel Pick up Lift up the foot Placing the Panel

Dispose the Panel Putting the Foot Down Remove the Panels

STEP 03 Set Target

* To Minimize Needle pricks through reducing Needle pricks occuring at Zigzag machin

STEP 04 Root course analysis

MAN MATERIAL
* Changing Threads while
switching on the machine.

* Handing issues.
 MAN MATERIAL
* Changing Threads while
switching on the machine.

* Handing issues.

MACHINE

* Unavailability of finger guards -

existing finger guard (which is ENVIRONMENT
the foot) only protects the index
finger.
- other fingers get pricked.

* Ability to put the finger closer

to the needle.

STEP 05 Developing Countermeasures

1 an attachment around the needle to cover whole needle so that the other fingers will not ge
2 change the Training method of handling part
3 senser to autostop/alarm the machine when a finger gets closer to the needle
4 Use of thimble
& so to imrpove moral of the employees

February March April

Finger Count Operation Finger Count Operation
Middle 1 Zigzag Middle 1 Side seam
Middle 1 Single needle Small 1 Zigzag
0 0 0 0 0 0
Index 2 0
Index 1 Zigzag Thumb 1 Bartag
Overlock
Index 1 Overlock Index 1
Thumb 1
0 0 0 0 0 Overlock
0 0 0 0 0 0

Total
2 Count of machines 8
4 in A
0 Count of machines 9
2 in B
 4
1
2
1
1
0
17
Prioritized problem

Total count
3
5
2

Placing the Panel Putting down the Foot Sewing

Remove the Panels Lift up the Foot

pricks occuring at Zigzag machine by August 2nd

METHOD
* When sewing the joints of the
panels, using less joint lengths
than reccomended.( finger
reaches to the needle)
 METHOD
* When sewing the joints of the
panels, using less joint lengths
than reccomended.( finger
reaches to the needle)

High Number of Needle pricks

from Zigzag machine

NVIRONMENT

so that the other fingers will not get affected

s closer to the needle

 April
Finger Count
Index 1
Index 2
0 0
0
Middle 1
Index 1

Ring 1
0 0
oritized problem
mber of Needle pricks
Zigzag machine