Analyse Phase:
In the previous Measure Phase we looked at the extent of the problem regarding sensor failures and also the current process map in a Recovery state.
Here in the Analyse phase the team looked at how the ideal process map should look. This takes into account continuous batch filling from start to finish, without any need for a batch recovery.
We also completed an Ishikawa or fishbone event on a failed grade A Isolator sensor. Here, we looked at each and every possible reason for component failure. At this stage it is looking like there will be numerous mini projects resulting from this event in order to rule out some of the suggestions. These cannot be completed at this time due to the timeframe for completion of this Green Belt project and also the resources required for those minor projects. These will be noted and referred to in the recommendations section of the project report.
The biggest event and also the one which took up the most time during this phase was the FMECA event. Where some companies just do a FMEA, we also bring into play the Criticality factor. The preparation hours for this event was extensive and also the commitment by the team during the event is to be commended. The event was held over almost two days with subject matter experts from other departments like Tech Ops and Engineering called on to answer any questions we had on occasion
The team are now focusing on the next Improve phase. The production timeslot has been booked on the line, we will need to be well prepared to get our testing completed in the time provided.
Here in the Analyse phase the team looked at how the ideal process map should look. This takes into account continuous batch filling from start to finish, without any need for a batch recovery.
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Future State Process Map
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| Ishikawa Diagram |
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Sample section of the FMECA file
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