Although you may start the A3 Problem-Solving process by yourself, it will eventu-ally require you to include people from your area or other departments, especieventu-ally
EGG WASHER
Band-Aids
Figure 8.2 Real root cause is neglected.
Countermeasures ◾ 63
There are two ways to approach brainstorming countermeasures. The first is to gather a group of people together to represent your area, other areas that could be impacted by this problem, and areas that are not affected by the prob-lem to brainstorm possible countermeasures. The second is to have that same group of people start the brainstorming process in isolation.
Gathering everyone together at the beginning makes it easier for the facilitator to explain the rules and process that will be used during the session. The draw-back to this approach is that you may not get full utilization of a person’s creativ-ity. Many people, including myself, need time for the idea or situation to mull around in our heads before we can effectively participate in this type of activity.
My best ideas come when I am taking a shower or walking my dogs. Walking my dogs has been the source of many great ideas for my daily work. There are other people who may be asked to participate in the brainstorming process because of their knowledge of the process. Keep in mind that although they may be very knowledgeable, they may also be shy or unwilling to expose themselves to ridicule if one of their ideas is seen as ridiculous by members of the group.
After gathering everyone together, start by reviewing flip charts of the Theme, Problem Situation, Target, and 5-Why chain so that everyone has the same
understanding. Once everyone is on the same track, give the group a couple of minutes to think about the situation before beginning the brainstorming pro-cess. Providing a few minutes for reflection before the brainstorming process is like priming the carburetor on your lawnmower before you pull the starter cord.
Priming the carburetor pushes fuel into the carburetor so that you do not have to pull the cord as many times to get the engine to start.
The second method for beginning a brainstorming session is to distribute a copy of the A3 that has the Theme, Problem Situation, Target, and Cause Analysis sections completed, along with instructions for generating possible countermea-sures for the problem. The instructions should also include a “no later than” date for each person to return their list of possible countermeasures. This method provides the necessary time for those who need to mull things over before par-ticipating in this type of activity. It also protects those who are shy about sharing ideas openly with the group.
Once everyone has provided a list, you should schedule a meeting to gather everyone together to complete the countermeasure process. In addition to the flip charts that were discussed in the previous method, you will need to post flip charts with all of the possible countermeasures that were submitted.
Regardless of which method you use, the procedure is the same once the group meets. During the meeting you should review the A3 process again and all pos-sible countermeasures that were submitted. Ask the participants to consider pospos-sible actions that will neutralize each statement in the 5-Why chain or fish-bone diagram.
Asking group members to think about each line in the 5-Why chain as they brain-storm will ensure a good mix of both short-term and long-term countermeasures.
Using a process called “round robin,” you can quickly facilitate getting ideas for the possible countermeasures. Start at one end of the group and progress
around the room asking for additional input. Continue going around the room until all ideas have been exhausted.
All rules normally associated with brainstorming apply: Stress quantity over quality, do not judge ideas, list ideas as swiftly and accurately as you can, and allow piggybacking (building on someone else’s idea to create a new idea).
There was one idea that was submitted during a countermeasure brainstorm-ing session for a paint problem. One of the problem’s causes was that the paint was getting thick because the paint was too cold. During the session, one of the participants blurted out, “Use hot pink paint!” Although the rules of brainstorming prohibit judging ideas, the group gave a chuckle. Piggybacking on hot pink paint, someone came up with wrapping heat trace around the paint lines that feed the paint booth to keep the cold temperatures from affecting the viscosity of the paint.
The key to facilitating an A3 brainstorming session is not to let it drag on too long. Once the group has exhausted its creativity, do not continue to prod them for more ideas. The perception will be that you have a countermeasure in mind that they have not identified. During a brainstorming session, you can gener-ate so many ideas that the group can feel overwhelmed, so you need to narrow the list to a manageable number. Figure 8.3 shows a list of countermeasures that were brainstormed for paint spits on frames leaving the paint department on Tuesdays and Thursdays.
Add more paint solvent to paint Increase the speed of the mix tank agitator Purchase paint that can be applied at lower temperatures
Relocate paint line to another area of the plant
Change the paint shift schedule to avoid early morning
Install drive-through plastic barrier in front of overhead door
Create a storage area for incoming paint on the other side of the plant
Relocate paint feed line to the other side of the paint booth away from overhead door.
Require material handlers to take the long way around when receiving paint
Run the paint department around the clock Change to a powder coat system
Insulate paint feed lines Insulate paint mixing vats
Work overtime to get enough good parts Build wall between overhead door & paint Relocate overhead door & block off opening Close plant and relocate to warmer climate Outsource parts painting in the winter months Place electric blanket over paint mix tank Paint parts with ‘HOT PINK’ paint Direct space heaters at paint feed lines
Wrap paint feed line in heat trace tape Turn up thermostat in paint area
Close off heat ducts in other areas of the plant to force more warm air to the paint area Cover paint feed lines with tin foil to deflect cold
Countermeasure List for Paint Spit Problem
Figure 8.3 List of countermeasures.
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