Like, while rolling out a new-procedure (say implementing FMEA procedure)... what are the step/trick(s) of aiming for simplicity & completeness of the implementation.
while implementation of FMEA, failure modes cannot be comprehensive without "participation of team & mapping of process details"; BUT, the shop-floor person views process mapping as additional documentation and additional time spent...
Now if we compromise above two steps, then effectiveness of FMEA is at stake and if its bulldozed, then participation will not be voluntary....!!! Either way it just becomes a mere document...
Now there has been detailed unit/team wise training-orientation-case study sessions
. so taking people onboard is not the issue. (now if it was expected to be steered by people who matter, well that is what is missing; But for sure, nothing technical/conceptual/procedural is not missing
)
while implementation of FMEA, failure modes cannot be comprehensive without "participation of team & mapping of process details"; BUT, the shop-floor person views process mapping as additional documentation and additional time spent...
Now if we compromise above two steps, then effectiveness of FMEA is at stake and if its bulldozed, then participation will not be voluntary....!!! Either way it just becomes a mere document...
Now there has been detailed unit/team wise training-orientation-case study sessions
. so taking people onboard is not the issue. (now if it was expected to be steered by people who matter, well that is what is missing; But for sure, nothing technical/conceptual/procedural is not missing)
Leading with the newly designed documented procedure is a mistake.
First sell the idea of involving a cross-functional team in analyzing the possible failure modes and their effects to avoid problems in production and with customers.
Let the participants enjoy the sessions facilitated by someone who is expert in FMEA on a product or process design of their choice (perhaps after some training by an FMEA on familiar product such as a flashlight).
Ask the participants to note down what they see as important steps in the processes and the requirements for its success.
Nominate the natural leader from this session as the process owner.
Gather these notes and work with the process owner to deliver a one-page flowcharted procedure (with swimlanes to show who does what) supported by a spreadsheet that will become the FMEA procedure for ongoing use, improvement and simplification.
You will be interfacing this procedure to your management system's one-page procedures for designing products (with simplification), design production processes (with mistake proofing?) and the preventive action process again in consultation with the relevant process owners.
Simplification takes a lot of effort and has to be an ongoing objective.
John
