FI STEP 3

ANALYZE CAUSES
Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
FI STEP 3 – ANALYZE CAUSES
OPL N.:
N. FI 3-01 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi

PURPOSE
• Determine remaining contributing causes to take improvement action against
PRODUCTS/TOOLS
0. Phenomena & Work Point Analysis (already used during Step 1 & 2)
1. Check available reapplications (kaizen & MP3)
2. Why-Why Analysis (OPL FI 3-02)
3. Fishbone Analysis (OPL FI 3-03)
4. Cause-Effect Analysis (OPL FI 3-04)
5. P-M Analysis (OPL FI 3-05)
TIPS
1. Restore basic conditions before jumping into root-cause analysis
2. Stop analysis when root-cause is “actionable” (specific countermeasure found)
3. Escalate the analysis tools based on complexity (see below)

cause
cause
cause cause cause cause
cause

cause
complexity

Why-Why Fishbone
Cause Effect
Why-Why P-M Analysis

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Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
WHY – WHY ANALYSIS
OPL N.:
N. FI 3-02 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi

STEPS
1. Describe observable phenomenon to analyze (a sketch is recommended)
2. Ask why until “actionable” root-causes are identified (normally 5 times is ok)
3. Make field check after each why to screen causes (exclude those not true)
4. Put in place countermeasures that eliminate the root-cause
(ask yourself: “is this really enough to avoid it will happen again?)
1st Why 2nd Why 3rd Why 4th Why Field Check 5th Why
Suction
Seal Cup
between Wear
No Wear
Pulling Suction
Force Cup and Suction
Not Carton Cup
Strong inadequate No Damage
Enough Damaged
Vacuum Suction
Force Cup Could be
Not Inadequate
High Material
Enough
Phenomenon Poor Dust
Carton on Yes
Surface Carton
Condition
Scratches
on carton Yes
…
Missing
Cartons
Carton Sticking
To Each Surface
Other Finish
outside Not True
Forces Holding Vacuum tolerance
Holding Fingers Setting
Carton Miss too low
too Adjusted No
high Vacuum
Holding Line
Frame Leaks No
Too
Tight
Suction
Cup
Too Small
Could be
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Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
FISHBONE ANALYSIS
OPL N.:
N. FI 3-03 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi

STEPS
1. Brainstorm all possible causes related to 5 M’s
(Machine, Material, Method, huMan, environMent)
2. Eliminated those not valid (evidence from available data / observation)
and then…
3. Use Cause-Effect An. to screen and prioritize remaining causes (OPL FI 3-04)
4. Analyze selected causes with Why-Why: cause
root-cause (OPL FI 3-02)
Machine
Filler Mechanical linkage
Position of nozzle
Position of centering device Nozzle wear

Height of nozzle in down position Fill Cylinder air Pressure

Material
Centering device slot machining
Cone pin bushings worn
Density
Speed of filler
Speed of Nozzle closure
Viscosity
Synchronization
Centering device to nozzle alignment

Surface Tension Shampoo spits out

side of the bottle
on fill Nozzle closure
Nozzle Cleaning

Start-up Centerline Settings Rebuild capability

Shut-down
Adherence to Centerlines Temperature

Method huMan environMent

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Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
CAUSE - EFFECT ANALYSIS
OPL N.:
N. FI 3-04 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi
NOZZLE CLOSSING -- TOO FAST
STEPS O-ring
1. Describe effect (sketch helps) Nozzle Lockup Nozzle
2. Write down possible cause
3. Explain possible cause-effect link Nozzle Terminal

4. Specify type of supporting info Shampoo

Drip Forming

(1  5 = decreasing probability) Air Flow

Air Flow
5. Check thesis (simulate) Shampoo Bottle

6. Summarize conclusions
7. If cause is not actionable go to Why-Why

Cause Effect

Shampoo drips on the side of

2 Speed of Closure the bottle. 1

TYPE OF CHECK CHECK DETAILS

X 1 Direct observation test The air resistance causes the

2 Evidence from collected data Thesis accelerating material to flatten
and be dispersed to form a drop.
3
4 3 Expert’s experience
4 Theoretically possible
5 Others Check Put a needle valve on the closure air
method to supply line and determine if the reduce
be used speed eliminates the drip problem.
Already existing reference standard
5
None Results of Drip problem eliminated !!!
the check

Already existing control method This solution makes the machine less
None Conclusion sensitive to the other contributing factors.
6
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Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
P-M ANALYSIS OVERVIEW
OPL N.:
N. FI 3-05 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi

What does P-M Analysis stand for ?

Phenomena Deviations from normal to abnormal state
P
Physical Physical analysis to understand the
physical principles behind an abnormal
event (the phenomenon).

Mechanism Understand the mechanisms of equipment

equipMent Understand the mechanics of abnormal Phenomena
M huMan
Material Understand the relations between the abnormal
Method event and the five production inputs (5Ms)

ANALYSIS Analyze causes and effects

What is Physical Analysis ?

• Physical Analysis uses the equipment and process operating
principles to clarify how various parts of the equipment or process
interacts to generate abnormal phenomena.

• Physical analysis does not look for causes but tries to

understand the deviation from normal.
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FI STEP 4
PLAN IMPROVEMENT
Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
FI STEP 4 – PLAN IMPROVEMENT
OPL N.:
N. FI 4-01 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi

PURPOSE
• Define a clear action plan to eliminate all unsolved root-causes
PRODUCTS/TOOLS
1. Compare multiple alternatives
2. Evaluate cost and benefit
3. Check feasibility (Change Management approval process)
4. Define resources and timing
TIPS
1. EOW (Enlarge Operating Window): act on Material or huMan as your last chance
improvements on equipMent & Method are normally cheaper and less fluctuating
2. Target to eliminate the root-cause forever (avoid any potential recurrence !!!)
3. Calculate benefit as 1 year saving + any “non $-able” PQDSM gain
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FI STEP 5
IMPLEMENT IMPROVEMENT
Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
FI STEP 5 – IMPLEMENT IMPROVEMENT
OPL N.:
N. FI 5-01 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi

PURPOSE
• Execute the action plan to eliminate all unsolved root-causes
PRODUCTS/TOOLS
1. Check materials and tools
2. Collect available OPL’s and Job Aids (including JSA/JSP)
3. Quick Risk Prediction
4. Execute the plan
5. Document Improvement (kaizen & MP3)
6. Check equivalent equipment and recommend reapplication (push mode)
TIPS
1. Whenever possible avoid implementing improvements all at once (ideally test and
verify the effect of each one before moving forward)
2. No one knows better than you where your improvements should be reapplied !!!

REAPPLICATION
KAIZEN / MP3
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FI STEP 6
CHECK RESULTS
Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
FI STEP 6 – CHECK RESULTS
OPL N.:
N. FI 6-01 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi

PURPOSE
• Check results vs. time and decide next FI Step to run
PRODUCTS/TOOLS
1. Daily tracking sheets
TIPS
1. Set a meaningful baseline (significant period of time)
2. Note on the charts each relevant action (eliminated abnormalities, implemented
improvements, variation of any impacting factor, etc…)

Step 6 : Check results

6.1 Evaluate results vs. time

6.2 Have
Targets been Go step 7
achieved ? Yes
Go step 3

No
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FI STEP 7
CONSOLIDATE GAINS
Rakona Plant ONE POINT LESSON
SUBJECT:
SUBJECT
FI STEP 7 – CONSOLIDATE GAINS
OPL N.:
N. FI 7-01 ORGANIZATION:
ORGANIZATION Focused Improvement Pillar Team Rakona
DATE:
DATE March 11, 2005 AUTHOR:
AUTHOR Luca Schianchi

PURPOSE
•
Standardize improvements to ensure problem will not surface again
•
Maximize benefit through reapplication This tool drives you through Step 7 and
is the best summary of the whole FI
1
Visually explain why the 2
loss was selected Explain the specific
(impact on business) problem redefined
during Step 1

3
Describe observed 4
phenomena … Sketch main
improvements …
… list relevant
factors

… and root-causes … and list them

6
5
Show results vs. time Standardization
&
7 Reapplication plan
Future plan
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