Toyota 8 step A3

A3 No. and Name Team members (name & role) Stakeholders (name & role) Department Organisation objective
Shaping issue at press no.15 1. Mr.Heshan, Mr.Asiri, Mr.Maduka, Continuous production with less BD & delays
Mr.Sandeepa 1. Mr.Thushara Engineering
2. Mr.Pasan 2. Mr. Technical
Team Leader (name & 'phone ext) 3. Mr. 3. Mr. Production Start date & planned duration
4. Mr. 4. Mr. Planning 13-02-2023, 1 Month

1. Clarify the problem 4. Analyse the Root Cause 7. Monitor Results & Process
Is: Shaping issue at press no.15

Is not: Other issues in press no.15 & all issues in other presses
Machine

Topring seal leakage

Problem statement: Tyres are being scrpped with shaping diffects continuously in press no.15
Water accumulating in the bladder

Non return valve malfunction

Piston valve bypassing

HPS flushing not working

Circulation drain not working

Shaping pressure variation

Man Pneumatic pressure droppage

2. Breakdown the problem No proper initial shaping Uncontrolled shaping

Excess inner paint Shaping delay

Shaping issue at press no.15

Using wrong bladders High guaged inner liner

Thread & sidewall low guage coat off or loose coat ply

Top ring down height Missing cord

8. Standardise & Share Success

Method Green tyre over diameter

Ply guage

Material

5. Develop Countermeasures

6. Implement Countermeasure

3. Set the Target

1 Checking all the machine related possible causes one by one to identify the real
root cause/s related to the machine within a week.
2 Observing the possibilities to occure the Man, Method & Material related possible
causes to take necessary actions within the same time period allocated to above.
 Toyota 8 step A3

4
 Machine

Topring seal leakage

Water accumulating in the bladder

Non return valve malfunction

Piston valve bypassing

HPS flushing not working

Circulation drain not working

Shaping pressure variat

Man Pneumatic pressure dr

No proper initial shaping Uncontrolled sh

Excess inner paint Shaping

Using wrong bladders High guaged

Thread & sidewall low guage coat off or loose

Top ring down height Missing cord

Method Green tyre over diamet

Ply guage
Material
age

n the bladder

e malfunction

ve bypassing

shing not working

ation drain not working

haping pressure variation

Pneumatic pressure droppage

Uncontrolled shaping

Shaping delay

Shaping issue at press no.15

High guaged inner liner

coat off or loose coat ply

Missing cord

Green tyre over diameter

Ply guage
Material