Problem-Free Engineering

5141 reads

Tomoo Sugiyama , Director at Yamaha Motor company defined a new approach to improvement activity. He called it Problem-free Engineering.

Sociological research proves that any idea can be popularized by  presenting it in the form of  a buzz word. Sugiyama called is '' Problem-Free Engineering'' .  Toyota Production System uses such words like Just-in-time, Kanban etc.

There are three basic problems at the workplace:  Waste, Inconsistency and Irrationality.  Problem-free Engineering strives to improve the workplace by reducing waste, inconsistency and irrationality to zero . The basic elements of problem-free engineering can be expressed by completing the buzz word '' __________-free Engineering'' with any form of waste , inconsistency and irrationality.

Walk - Free Engineering means eliminating excessive walking

Conveyor -free Engineering means eliminating excessive use of conveyors

Bottleneck-free Engineering means eliminating bottlenecks

Problem is typically defined as the any variation between the actual situation and the established standards or desired standards.

Some examples of Problem Free-Engineering are

People

  • Look-free (eliminate excessive looking)
  • Search- free
  • Walk- free
  • Stacking- free
  • Wasted motion - free
  • Unused creativity - free

Machines/Equipment

  • Air- free
  • Conveyor - free
  • Air cut - free
  • Air press - free
  • Oil pan - free
  • Corner - free
  • Dust - free
  • Toolbox - free
  • Energy - free

Method

  • Bottleneck - free
  • Hunger- free
  • Inventory - free
  • Changeover - free

Material / Parts

  • Bolt- free
  • Burr- free
  • Weight - free
  • Spot weld - free
  • Parts - free
  • Welding - free

Quality

  • Defect - free
  • Nonstandard - free

The foundation of workplace improvement is laid by first detecting the problem and recording the problem. They are recorded in the form of big 3 memo. Eg: You might find on the floor an operator walking longer distance to pick up a part which is a waste of time. This problem of excessive walking is recorded in a memo .Plenty of thought is then applied to eliminate these problems (eg walking ) by analyzing the root cause and suggesting actions that prevent recurrence of deviations from desired or established standards.

Problem-free Engineering and problem solving usually go hand-in-hand. Various tools like 5 Whys , Industrial Engineering techniques and Quality circles are used to reduce or eliminate problems.

Winning can be a matter of luck, but losing is not.... The root cause of problems is not due to accident or luck. There is always a possibility of identifying a root cause and creating a room for improvement.

 

 

 

Trending

202
Johngreathouse's picture

How Trying To Assassinate Hitler Led To The Beatles’ Sgt. Pepper

A version of this article previously appeared in Forbes. I recently enjoyed John Covach’s History Of Rock Coursera course. In an early lecture, he explains how the Nazis’ desire to protect Hitler from assignation led to the invention of
97
mashable's picture

Google just slashed the price on its massive storage plans with Google One upgrade

Google's storage plans are getting cheaper. The company has launched a new storage plan called Google One, which offers significantly better deals than Google Drive storage plans. There's no need to switch, because all current Drive storage
86
johnsullivan's picture

HireVue, Indeed Unveil Pre-Hire Assessment Solutions Born Out of Acquisitions

One did it with a new acquisition. MindX, a game-based assessments company based in London, has been acquired by HireVue, best known as one of the oldest video interviewing solutions. The announcement was made last week. “The MindX game-based
368
changethis's picture

Start Imagining a Future of Human + Machine

“In the first wave of transformation, businesses standardized processes. Think Henry Ford and the assembly line, where steps in the overall process were broken down, measured, and optimized to achieve gains in efficiency. The second wave of
128
jackcanfield's picture

Try This Simple Night Meditation Called "The Evening Review"

Successful people maintain a positive focus in life no matter what is going on around them. They stay focused on their past successes rather than their past failures, and on the next action steps that will get them closer to the fulfillment of their
112
davecrenshaw's picture

How far would you go for a friend?

I recently witnessed an act of compassion and friendship so unexpected, it moved me to tears. And it happened in a very unlikely place: Pelican Bay super-maximum security prison. I support a program called Defy Ventures, an organization that works
113
johnsullivan's picture

Here We Go Again – LinkedIn Updates Its User Agreement

There are times in my life when I hate that I am right about something. Like the time I thought an employee was stealing from my store back in the day and two days later I caught them doing just...
234
changethis's picture

How Women Rise: Helping Women Change the Behaviors that Get in Their Way

“It’s not surprising that many of the behaviors that hold men and women back would be different. After all, women often have very different experiences at work. And experience shapes habits and responses.Familiar habits and responses may feel
196
danielhpink's picture

PINKCAST: This is how (not) to calm your nerves

There are two kinds of people in the world: Those who feel a little nervous before big presentations . . . and liars.For all of us in the first group, this 86-second Pinkcast — it’s a phone show, folks! — offers a simple, science-based technique for