Quick Kaizen Sheet QK No: Area: Equipment: Lead By: Assisted By: Date Started:

Which Pillar? Bundler tali seling sarman

HS E CS FI AM PM EEM TPQC PD CR 25/07/17
1) Problem sketch & description: (80% sketch & 20% words) 2) List the possible causes of the problem:
Tali seling putus saat Normal running Seling keluar rel
saat terjadi
hentakan
1 Tali seling terkena frame akibat keluar dari pulley

2 Bandul tersangkut pada cover

Sensor di geser maju
agar motor driving
roller start lebih awal
3 Sliding Dancing roller macet

Dancing roller 4 Dancing roller macet

bergerak sampai
habis dan
tersangkut rel
5
Motor driving roller

4) Action plan to remove problem: 5) Date Complete: 3) Verify which possible cause is a real cause:

Action (Risk Assessement Required - see page 2) Who When Done? What to Check How to Check Findings Cause?
Tali seling keluar dari pulley terjadi saat dancing roller yang bergerak
maksimal saat running TCVN 1210 mm,penyebabnya karena saat tape
bergerak,Driving roller terlambat start sehingga dancing roller bergerak
Icen 12/7/2017 Done 1 Tali seling Lihat posisi tali pada pulley
Keluar dari
Pulley Y □ N□
sampai batas maksimal sehingga terjadi hentakan yang menyebabkan
seling keluar dari pulley.Hentakan ini juga menyebabkan tape sering
putus saat TCVN.
2 Bandul Lihat posisi bandul pada cover Tidak tersangkut Y □ N□
1
Action yang dilakukan dengan cara mengeser maju sensor start driving
roller,sehingga saat tape bergerak driving roller cepat berputar sehingga
menghindari dancing roller bergerak maksimal ( terpentok body rel )
3 Dancing roller Lihat pergerakkan harus lancar Lancar Y □ N□
4 Dancing roller Dancing roller berputar lancar Lancar Y □ N□
5 5 Y □ N□
6 6 Y □ N□
7 7 Y □ N□

FRM_FI_QK Quick Kaizen Sheet_4-2 © BPB Ltd 2009 Page 1 of 3


Risk Assessment Sheet:
Step 1 - Identify Hazards
What are the additional hazards?
Spot hazards by:
• walking around the area
Note 1 - Risk Assessors should be confident that they have sufficient Assessed By: Date:
Note 2 - This risk assessment is to be used in all
knowledge or experience to complete this process effectively. If in
cases.
doubt Ask.
Step 2 - Identify Impact / those at risk Step 3 - Evaluate the risk Step 4 - Control the risk
Who / what might be harmed and how? Evaluate consequence and likelihood of occurrence Take action to eliminate / reduce the risk
Think mainly about groups of people that could be harmed, then Evaluate the consequence (Risk Severity) if an accident ROP Think what measures are already in place to reduce the likelihood of harm or make any harm less serious.
think about the process, product and machine. occurs, plus the likelihood (ROP) that an accident Can they be used or enhanced to deal with this additional hazard?

RS
• thinking about proposed modifications Remember: occurs. Use the scales shown below; consequence 10 8 6 4 2 You need to make sure you have reduced any risks "so far as is reasonably practical".
• asking fellow employees • Normal running, abnormal conditions (operator should be based on the most likely outcome (not the Compare what you are doing with good practice and if there is a difference list what needs to be done.
• discussing with your safety representative intervention), maintenance activity worst case). Likelihood rating should assume that any 100 1000 800 600 400 200 While completing the action were any further hazards found?
• checking manufacturers instructions • people may not be in the work place all the time existing control measures are in place; "if the task is On completion of the action carry out another risk assessment.
• visitors and contractors done every day; what is the likelihood of injury?" 40 400 320 240 160 80
Don't forget long term risks Say how the hazard could cause harm Multiply the two values to get an overall risk score.
Prioritise hazards with the highest risk score to be dealt 21 210 168 126 84 42
with first.
8 80 64 48 32 16

1 10 8 6 4 2

Product / ROP - Likelihood Risk Level before Done (Re-assess)

Risk
People Machine RS - Consequence Rating if RL is 64 or less proceed if not contact
Reduction
Process Rating = RS x ROP manager

May cause death <-- 100 (Only on people issues) Inevitable - Many time / year: 10

May cause a severe Action RS ROP RL

accident
<-- 40 (Only on people issues) Very High - 1 or 2 / year: 8 What control measure is Action RR =
80 or above = control by
May cause machine Will cause all product necessary? by when (100 - (10 - 8 after = RL
May cause a LTA <-- 21 Probable - 1 / 2 years: 6 whom
Action / breakdown to be scrapped
measure required 40 - 21 - 6 - 4 - RS x before -
Hazard May cause an non May cause reduced May cause some
Number LTA performance damage to product
<-- 8 Less Probable - 1 / 5 years: 4 - 8 - 1) 2) ROP RL after
i.e. 1.1, May cause a minor May cause minor
1.2 etc May cause defects <-- 1 Least Probable - > 1 / 5 years: 2
injury damage
PEOPLE

Total People Risk Reduction:

MACHINE

Total Machine Risk Reduction:

PRODUCT / PROCESS

Total Product / Process Risk Reduction:

FRM_FI_QK Quick Kaizen Sheet_4-2 © BPB Ltd 2009 Page 2 of 3

Quick Kaizen Form Revision History
Version No Date Name Comments
4-3 008/07/2011 D C Tyeson Logo updated Gypse Way
4-2 2/4/2010 Y. Seguillon Pillar references added - Total Risk Reduction added
4-1 1/18/2010 Y. Seguillon Clarification on notes - font increase
4-0 1/14/2010 Y. Seguillon Risk level definition and score in line with Saint Gobain Gyproc HS Standard
3-2 1/31/2007 A.Shaw Saint Gobain branding added
3-1 1/24/2007 A.Shaw Revision filename added to footer to support version control as part of uploading to Livelink and WCM intranet
3-0 11/27/2006 C. Poole Layout revision with detail to help use in all boxes, risk assessment added on second sheet and revision history sheet added.
Please ensure that new version details appear at the top of this list by inserting a row above row 4 and typing the notes into that space

No part of this publication may be reproduced in any material form (including photocopying or storing it in any medium by electronic means and whether or not transiently or incidentally to
some other use of this publication) without the written permission of the copyright owner except in accordance with the terms of the Copyright Designs and Patents Act 1988. Applications
for the copyright owner’s written permission should be addressed to the publisher.

FRM_FI_QK Quick Kaizen Sheet_4-2 © BPB Ltd 2009 Page 3 of 3