What do you do if you encounter a problem on the manufacturing floor?

Identify the scope and impact of the problem by assessing its magnitude and severity, and determine whether it is a minor issue that affects a single machine or workstation, or if it has broader implications that can disrupt the entire production process. Consider the potential consequences of the problem, such as production delays, quality issues, or safety concerns. Collect relevant information about the problem, including its symptoms, root causes, and potential solutions, then consult machine operators, maintenance technicians, or other personnel who have firsthand knowledge of the equipment or process involved, if data from production logs, sensors, or quality control systems to gain insights into the problem's nature and extent!

Complementando !! Ao identificar um problema no Ch?o de Fábrica , é fundamental agilidade na análise e tomada de a??es! Muitas vezes um problema bem mapeado se transforma em oportunidades para outras opera??es ! Ouvir os colaboradores envolvidos no problema , identificar a causa raiz, fortalecendo um ambiente colaborativo entre as áreas de Engenharia Industrial , Desenvolvimento e Produ??o. Após implementado a a??o de conten??o ( prioridade) e preven??o para que o problema n?o volte a acontecer , recomendo uma Auditoria de Processo focada , para assegurar a robustez das a??es .

Assess The Situation. When encountering a problem on the manufacturing floor, the first step is to assess the situation. Take a moment to observe and understand the nature of the issue at hand. Identify what exactly is going wrong and how it is affecting production or quality. Consider whether this problem is isolated or if it has potential to escalate and impact other areas of the operation. Look for any immediate safety concerns that need to be addressed before proceeding with troubleshooting. By thoroughly assessing the situation, you can gather crucial information that will guide your next steps in resolving the problem effectively and efficiently. This initial step sets the foundation for a well-informed approach.

Start by assessing the integrity of operational data generated from the floor and use that as a starting point to shape the recovery plan. Fix integrity issues with the data but actions in the recovery plan need to be backed by hard data, and projected outcomes need to be quantified.

Conduct A Root Cause Analysis. When faced with a problem on the manufacturing floor, it is crucial to conduct a root cause analysis to determine the underlying issue causing the problem. This involves investigating all possible factors that could have contributed to the issue, such as equipment malfunctions, human error, or process failures. By thoroughly examining each potential cause, you can identify the true root of the problem and develop effective solutions to prevent it from recurring in the future. Root cause analysis not only helps address immediate issues but also improves overall efficiency and quality in the manufacturing process by identifying and resolving underlying problems that may have gone unnoticed.

Once you have reliable data, use that to narrow down upon a set of low-capital, high-impact improvement opportunities. The recommendations will need to be actionable and will need to be prioritized in order of impact and implementation costs. The main goal is to constantly ask the question "How can I produce one extra part the next hour?", use this mindset to identify and quantify improvement opportunities.

Conduct root cause analysis to understand the issue and prevent re-occurrence. In my experience analysing the issue (scope and impact) then cause, and adjust processes will return best possible outcomes.

Aplicar as Ferramentas necessárias para uma análise eficiênte com objetivo de encontrar a causa raiz do problema. Envolvimento do time como todo é fundamental para uma boa análise, principalmente as pessoas ligadas diretamente!!!

I agree but the long term effects can cause further hold ups. The rca should come into effect after the issue has been resolved. Production =money. Let’s get moving and keep producing going as we as a whole determine how to prevent such problems in the future.

Notify The Supervisor. If you encounter a problem on the manufacturing floor that you are unable to resolve on your own, it is important to notify your supervisor immediately. Your supervisor is there to support you and help address any issues that may arise during production. By informing your supervisor of the problem, they can assess the situation, provide guidance on how to resolve it, and make any necessary adjustments to ensure production continues smoothly. An employee should bring any work-related problem to the attention of his or her immediate supervisor as soon as possible so the problem may be resolved. Continuous improvement managers, shop floor supervisors, and engineers can analyze the production report.

Don’t hesitate to seek help if needed. Collaborate with experts, consultants, or industry peers to gain insights and improve your knowledge.

Consultar a equipe é uma prática essencial na resolu??o de problemas no ch?o de fábrica. O conhecimento coletivo e a experiência dos membros da equipe podem oferecer insights valiosos no diagnóstico e na solu??o de problemas. Eles podem ter observado sinais de alerta ou fatores contribuintes que podem n?o ser imediatamente óbvios para você. Além disso, o envolvimento da equipe promove um ambiente de trabalho colaborativo, incentivando a inova??o e o desenvolvimento de solu??es mais eficazes. Essa abordagem fortalece a equipe e melhora a capacidade de lidar com desafios de forma eficaz.

Ensuring the individuals who perform the job have a voice is imperative to effective solutions! Developing a culture of collaboration is vital to successful problem solving.

I agree, knowledge is power the stronger your team is the better the outcome. Keep and encourage input positive or negative. The more we know the better we are as a team and in the end this is a team effort.

If the problem affects production, consider implementing temporary workarounds to keep the process moving. However, prioritize safety and quality.

Se o problema afetar a produ??o, considere implementar solu??es temporárias para manter o processo em movimento. No entanto, priorize a seguran?a e a qualidade.

In my experience the more we know about the cause and effect of actions dictates the outcome. If everyone is on the same page the quicker we all can come to a solution. Input is key good or bad the more we know the easier it is to resolve an issue.

Once the root cause analysis is finished the first thing to do is to generate an alert (document that includes the date, the area, the problem, the corrective action and the systematic solution) have it signed for all the participants in the process and finally post it, with this action you assure that everyone knows about it and will know what to do if the corrective or the systematic action fails.

Após identificar o problema e consultar a equipe, é crucial implementar uma solu??o eficaz. Isso pode incluir reparo ou substitui??o de equipamentos, ajuste do fluxo de trabalho ou retreinamento da equipe, dependendo da natureza do problema. é importante garantir que as corre??es n?o sejam apenas solu??es temporárias, mas sim medidas sustentáveis que evitem recorrências. Documentar o processo de solu??o é essencial para referência futura e para fortalecer a resiliência geral das opera??es de fabrica??o. Essa abordagem garante uma resposta eficaz e promove a melhoria contínua no ambiente de trabalho.

Implemente monitoramento a nível operacional, tático e estratégico reduz as chances dos problemas retornarem. Isso pode ser feito través de: -Painéis com vis?es relevantes em Data Analytics -Opera??o assistida -A??es corretivas

I agree communication is key keep all channels open. Clarity is key from upper management to the bottom keep channels clear and relevant.

After implementing solutions and informing all the personal involved I normally start a PDCA cycle in the Check phase, this until I confirm in certain time that the process is stable again.

Fundamental manter o monitoramento do processo para garantir a eficácia, e para algum eventual desvio seja possível agir rapidamente evitando que o processo retorne para o ponto inicial.

What really important is to define the problem and the.impqct of it to the observed KPI's.One of the key observations is, the more precise you are in the problem description and the actions will be more logical towards the problem.

En atelier, face à un problème, commencez par l’identifier précisément. Discutez avec les opérateurs pour comprendre les sympt?mes. Communiquez avec l’équipe pour une vision partagée et évaluez les solutions possibles. Optez pour une méthode de résolution de problèmes éprouvée, comme les cinq pourquoi ou le diagramme d’Ishikawa, pour examiner les causes profondes. Implémentez la solution choisie avec des actions correctives et suivez les résultats pour confirmer la résolution du problème. Documentez tout le processus et les enseignements tirés pour améliorer les pratiques futures et prévenir la récurrence. L’approche proactive et collaborative est essentielle pour surmonter les défis efficacement.

If you encounter a problem on the manufacturing floor, the first step is to assess the situation calmly and carefully. Then, try to identify the root cause of the problem. Depending on the severity and nature of the issue, you might need to stop production temporarily to prevent further complications. It's important to communicate the problem promptly to the appropriate personnel, such as supervisors or maintenance staff, and work together to find a solution. Keeping clear records of the problem and its resolution can also help prevent similar issues in the future.