A3 Dojo: Share and Discuss A3s with Other Lean Thinkers

Message: HI Donald, Looks like you have progressed on your A3 since Dallas. I like the quantifiable GAP and breakdown. Is the crew breakdown A-D by shift? So are you saying its happening on all? Is there more than one Extruder, I see it say #27. Just looking for comparison data if applicable. In your process what exactly is happening at the point of concern? Can you be more specific in your problem statement as to what is the "bad thing" thats happening within that step of the process. If you can dial in a little more on that step then your target can be set to fix that point of concern. I like the way you have broken down your GAP into managable pieces. Knowing it will take other micro level A3's to eliminate the GAP. Also on the right side. I like the fact that you will be putting a measure in place to track the effectiveness of the countermeasure (new std work). Its one thing to write new standardized work, but we must ensure we engage everyone in the process and track. I think for your first A3 you have done well articulating some of the key points we talked about in the Managing to Learn class. Please keep us posted on your progress and how this one contributed to the overall GAP reduction. Tracey

Message: We have 29 Extruders within facility. It was determined by our leadership team to tackle that particular line due to the volume of output and that it was a point of concern based off of previous history of scrap on that line. Yes, we have 4 crews that rotate and run the extruders (A - D crews) I see where I missed completely stating my problem statement and will update my go to gemba and problem statement after our first training session. Thank you for your input! Don

Message: Are there different parts that run on the Extruder or just one particular? Yes I think if you dial in on the point of occurrence it will help. Look forward to your progress.

Message: Assuming the print setup is your point of concern, establishing a standard setup procedure will certainly help. I would also suggest applying some of the SMED principles, particularly the focus on settings. Everything should try to be a setting and not an adjustment. By establishing settings for each adjustment point - the results are faster changes, more consistent quality, and a lower learning curve for the procedure.

Message: Is the lack of proper training a system wide promblem? How is training done on the outher extruders in the plant. Do you use a standardized training method like TWI? TWI is training within industry- see twi.org for more info