5 why
Where do 5 whys go?
5 whys go on the action log and are reviewed in the weekly 5 why meeting.
When should you create a maintenance plan versus a preventative maintenance plan?
A maintenance plan is a cheap part replacement. Example replacing packer lugs. A preventative maintenance plan required down time and is expense such as a packer over haul. The parts are not easily available so the maintenance must be planned.
Explain what makes a good quality 5why.
A 5 why must have the trigger, supporting evidence and the root cause. Be able to read it backwards and it makes sense.
What makes an affective PI?
An affective PI is an observable negative trend at the operator level.
Tell us about effect blockers.
An effect blocker is a temporary action put in place to assist but doesn't eliminate the root cause. Example - employee watching for open flaps until root cause determined.
Explain the 5 why routine.
BPM reviews it, it goes on the SDCA matrix and communicated in the shift handover meeting.
If parts fail due to forced deterioration, what actions outside of maintenance plan should be taken?
Find out what changed. Was there a change in personnel, material, lubricant, check for cleaning.
What is the difference between forced and natural deterioration?
Forced deterioration is wear and tear that could be avoided. Example would be if something was loose or out of alignment on packer. Natural deterioration is expected wear and tear due to the normal process.
Why does a 5 why branch?
It would branch when the root cause cannot be determined and you want to develop theories or if you have more than one root cause.
What tools do you use for 5 why
PI / reaction plan/ abnormality report/ PDCA. Abnormality report triggers on a larger block and on 180 minutes of downtime.
How do you know when you start a 5 why?
Start a 5 why when a PI trigger is red, the reaction plan doesn't solve it or if there is no reaction plan. Or if there is a block or if there is 30 mins of downtime.
What's the purpose of a 5 why?
To get to the root cause of a problem and solve it permanently
If you identify a skills gap in your area, what actions do you take?
Update an SOP, post an OPL or utilize SKAP
How do you and the team utilize the SDCA matrix?
We review the matrix, fill it out and compare how the machine centers are running.
How does your team know when to change a PI trigger?
When the PI becomes sustainable for a long period of time.
When would a 5 why be escalated to an abnormality report?
When the problem is complex and needs further analysis. Or if there is a large block or if there was extended downtime.
Identify a tools gap in your area, what actions would you take to eliminate it?
Work with BPM, develop a tool that would improve safety and or efficiency. Once implemented, team members should be trained, SOP updated, rolled out to the rest of the plant. Example would be the new conveyor shut off on GPI.