PROBLEM SOLVING A3 REPORT

WHIRLPOOL CORPORATION CONFIDENTIAL

TITLE -Originated:

Revised:

Problem Statement Countermeasures

Note:

Approver: Coach: Author:Author Email: Author Phone: Date: Date: Date:

For Proposed Layout Click here

Current Layout Click here

Kishore Y Chaphekar / Gopinath Jayaraj

Laguduvan R Jagadeesan

Arunkumar Ravindran, Rejitha Girish, Ashwini Bhondve, Chandika Das

Effective utilisation of Embedded software testing Lab - GTEC

Implementation

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Reflect / Document

Verification and Follow up

Target / Goal

Cause Analysis

The Software testing Lab is utilised for Software validation in Product by four categories--Fabric Care(FC),Dish (HC),Cooking (FP) and CAT (Connected appliance)

Current Scenario:Issues are related to infrastructure and Maintainence1. Lab is unorganized and unclean resulting in less workspace , less storage space area & is cluttered 2. There are no defined Standard operating procedure maintained in the Lab.3. Handling and Maintainence of Machines and Lab equipments /tools are not defined.4. There are issues related to Hygeine as there are water leaks and wetcloths placed after testing.5. The current placement of Variac is unsafe(Placed on top of chair /Machine)6. 3 PHASE and High Voltage transformers are placed near water valve.

1. To effectively use the Lab space.2.Provide a safe and Hygiene work space for the testers.3.Maintain Standard Operating procedure and storage space for Equipments4.Organize Test Station by identifying and storing the items used, maintaining the area and items, and sustain the new order.

S.No Current Issues

1 Inlet valve Issues - no threads, Water leakage

2

3 Water Heater - Water leakage

4

5

6

7

8

9 Power supply tripping issues - Connectivity Lab10 UWLAN range is not there inside the lab11 Basic cleaning is not done inside the Connectivity Lab12 Work station Tables are less in Connectivity Lab.

13 Basket for segregating /storing wet clothes and dry cloths

14 Dryer facility for drying the wet cloth

15 Time taken for Moving Machines from storage to Lab16 Guidelines for Equipment/Tools usage17 SOP for Lab

18 Placement of Cupboards and usage and cleanliness of the cupboard

1920

Lab Cupboard Placement - Current cupboard is not easy to access by all members

LAN / Phone connector is not properly installed. It will come out. Phone line are not working in all stations

Lab Lighting - Not bright or lights are getting fused quickly & AC Ventilation is not good.

3 Phase products or Transformers for Dryers or Cooking products should keep seperatly for safety reasons.

Dryer exhaust hose - Currently we don't have any exhaust. Need to place the exhaust

Trolley for Varic (Transformer) & California power supply - Currenly user placing in chair or on top of machine.

Responsible persons to solve Time line suggestion / Solution

Mayur Bhasin

Mayur Bhasin

Mayur Bhasin

Mayur Bhasin / Ashwini Pandey

Mayur Bhasin

Mayur Bhasin / Team Members

Mayur Bhasin Not feasible in current premises

Mayur Bhasin

Mayur BhasinMayur Bhasin / Ashwini PandeyMayur Bhasin / Team MembersMayur Bhasin / Team Members Designed for Machine placement

1) Need to fix the permanent stations for cooking product & Dryer.2) Separate place for Transformer & give only power plug for the product.

Machine is available .To be moved and placed

Severity

Current Layout - SQC & CAT

9 8 7 6 5

C HC HC HC H

GD1MD

GD1MD

GD1MD

GD1MD

GD1MD

C H

9 8 7 6 5

10 11 12 13 14

C HC HC HC

C C C

1MD1MD1MD1MD

1MD 1MD 1MD

SQC Lan Layout1~18 - Work StationsC -Cold Valve H - Hot ValveGD - Ground level Drain1FD - 1 feet hight drain1MD - 1 Meter hight drain - Available but Unaccessible area

- Equipments (Transformer)

GD1MD

10 11 12 13 14

1MD 1MD 1MD

SQC Lan Layout - Proposed1~18 - Work StationsC -Cold Valve, H - Hot ValveGD - Ground level Drain1MD - 1 Meter hight drain - - Move transformer to this space which is currently inside the cupboard . Also move the equipments(120V HV transformer - FP) to the same place. Use shelfs to storage & give output to socket (Station 15,16)(Remove the cupboard which i s present on top - which is Unaccessible)

GD1MD

GD1MD

GD1MD

GD1MD

GD1MD

C H C H C H C H

1MD1MD

C H

SQC Lab Changes required:

1) As per the layout - Create water connection (Hot & Cold), Water draining ( Ground Level & 1 meter height). Repair the current valve threads & Use cap to close unused valves.2) Remove cupboards which is currently present in top fo the stations, whcih is not accessible currently). Remove wooden piece near station 9 3) Move transformer to corner near SQC station 1 - This transformer is currently inside the cupboard . Also move the equipments (120V HV transformer - FP) to the same place. Use shelfs to storage & give output to socket (Station 15,16).4) Move cupboard to leftside. Now this full cupboard will be used to store the equipments5) Station 1 &2 platform height need to reduce or make same as other stations - 3 to 9.6) Design Trolley for Varic & California power supply. - (Refer Pondy PDC test lab)

CAT Lab change requirements:

1) Keep the 2 set of transformers in the corner b/w station 7 & 8. Keep output to station 6 & 7. Use shelf to keep it on top of it Equipments 2) Currently the Transformer which is b/w station 11 &12, move it to corner whcih is unaccessible or create one shelf on top of LAN ROUTER & move it,Just provide output near station 12.

optimization: 1) In SQC lab, we can keep 1 Ground level drain & 1 meter height drain for 2 work stations.

Current Layout - SQC & CAT

Proposed Layout - SQC & CAT

5 4 3 2 1(Dryer to dry

the test load)

C HC HC H

GD1MD

C H

GD1MD

GD1MD

GD1MD

7

5 4 3 2 1

14 14 16 17 18

C H CC HC H

C C C C H C H

GDGDGD1 FD

1FD1MD

1MD 1MD1MD 1MD

Cup boar

d

Equipments

SQC Lan Layout1~18 - Work StationsC -Cold Valve H - Hot ValveGD - Ground level Drain1FD - 1 feet hight drain1MD - 1 Meter hight drain - Available but Unaccessible area

- Equipments (Transformer)

76

14 15 16 17 18C H C H

GD1MD

1MD 1MD1MD 1MD

Cup boar

d

SQC Lan Layout - Proposed1~18 - Work StationsC -Cold Valve, H - Hot ValveGD - Ground level Drain1MD - 1 Meter hight drain - - Move transformer to this space which is currently inside the cupboard . Also move the equipments(120V HV transformer - FP) to the same place. Use shelfs to storage & give output to socket (Station 15,16)(Remove the cupboard which i s present on top - which is Unaccessible)

GD1MD

GD1MD

C H C H C H

1MD

GD1MD

76

SQC Lab Changes required:

1) As per the layout - Create water connection (Hot & Cold), Water draining ( Ground Level & 1 meter height). Repair the current valve threads & Use cap to close unused valves.2) Remove cupboards which is currently present in top fo the stations, whcih is not accessible currently). Remove wooden piece near station 9 3) Move transformer to corner near SQC station 1 - This transformer is currently inside the cupboard . Also move the equipments (120V HV transformer - FP) to the same place. Use shelfs to storage & give output to socket (Station 15,16).4) Move cupboard to leftside. Now this full cupboard will be used to store the equipments5) Station 1 &2 platform height need to reduce or make same as other stations - 3 to 9.6) Design Trolley for Varic & California power supply. - (Refer Pondy PDC test lab)

CAT Lab change requirements:

1) Keep the 2 set of transformers in the corner b/w station 7 & 8. Keep output to station 6 & 7. Use shelf to keep it on top of it Equipments 2) Currently the Transformer which is b/w station 11 &12, move it to corner whcih is unaccessible or create one shelf on top of LAN ROUTER & move it,Just provide output near station 12.

optimization: 1) In SQC lab, we can keep 1 Ground level drain & 1 meter height drain for 2 work stations.

Connected Appliance Lab Layout - Keep 1 transformer in this Unaccessible area

- Keep the 2 set of transformers in same place (B/w Station 7&8 gap. Use shelf to keep it on top of it Equipments - Wall

7

8

13

8

13

12

34

5

76

910

1112

CUPBOARDS

Connected Appliance Lab Layout - Available but Unaccessible area

- Equipments (Transformer, LAN router)

- Wall

Connected Appliance Lab Layout - Keep 1 transformer in this Unaccessible area

- Keep the 2 set of transformers in same place (B/w Station 7&8 gap. Use shelf to keep it on top of it Equipments - Wall

12

34

5

76

910

1112

CUPBOARDS

13

Fish Bone1 Environment

2 Safety

3 Tool Management

4 Product Availability

5 People

Fish Bone

a.Inlet valve Issues - no threads, Water leakageWater Heater - Water leakageLAN / Phone connector is not properly installed. It will come out. Phone line are not working in all stationsLab Lighting - Not bright or lights are getting fused quickly & AC Ventilation is not good.Basic cleaning is not done inside the LabUWLAN wifi range is not there inside the labDryer facility for drying the wet clothPower Supply Load Management--Tripping of Lines

3 Phase products or Transformers for Dryers or Cooking products should keep seperatly for safety reasons.Trolley for Varic (Transformer) & California power supply - Currenly user placing in chair or on top of machine.

Basket for segregating /storing wet clothes and dry clothsUnavailability of Proper storage for tools and Equipments.Accessability of Cupboards

Movement of Machine from storage area to Lab for Testing--Delay in movement

S.no Measure

1 Layout changes

2 Leverage of Machine

3 Powersupply Load Management---

4 SOP

5 Tool Storage and Management

6

7 Movement of Machines

Infrastructure addition(Trolley/Basket/Dryer/Weighing

machine/ Transformer placement)

Cause

Workstation are not organised

Machines are stored for future projects.

No Standard operating procedure for Lab Maintenenace

No Defined space for Tools storage and maintenance

No proper allocation of space for Workstation and Tools /Equipmentstorage

No information/Data base for Machine availability with Cross category team.Machines retained after testing within team become high

No proper document /awarness on the number of Loads/product that can be tested at a instance.Causing tripping of products.

Programers usage - Programmer Guidelines are not available.

Maintenance / proper storage for equipments & tools are not defined

Delay in movement of machines for testing from ground floor to 5th Floor.

Suggestions

Layout changes

No : of Loads to defined for machine testing

Layout/SOP

Layout

Define process to move machines

Photos,Layout diagramto be provided for overhaul of existing Lab

Only inprogress m/c should be in lab. Other machines to be stored in storage area or if it is not in use scrap it.

Database to be maintained for all the equipments/tools/machine in gtec.This will enable the leverage of tools and machine

SOP to be maintained and posted in prominent places of the Lab

1. Lab incharge / Team Lead to train the newcomers on usage of station and Tools - 2. Master List of Tools and team/Person responsible sheet.

S. No Type 1

Cost

No cost

Cost

No cost

Cost

Cost

Cost

Cost

2

No cost

3No cost

4

No cost

5

No cost

6CostCostCost

No cost

7No cost

- Main changes required- Need to close it in Priority.

Implementation - ProposalLayout Changes

Move cupboard to leftside. Now this full cupboard will be used to store the equipments

Station 1 &2 platform height need to reduce or make same as other stations - 3to9.Design Trolley for Varic & California power supply. - (Refer Pondy PDC test lab)

Leverage of Machine

Powersupply Load Management---No : of Loads to de defined for machine testingNeed to define SOP to SQC & CAT lab users about the load management for 120V products & transformer usages.SOP

Need to create standard operating procedure for product usage & process to follow.Tool Storage and Management

Need to create a process to maintain the tool storage & usage.Infrastructure addition(Trolley/Basket/Dryer/Weighing machine)Trolley need to buy to keep Variac & California power supply.Order 2 basket to store wet & dry cloth loadsNeed to order Weighing machine to check the load weight before testing.

Separate dryer needs to place in lab to dry the wet cloths - Closed. Machine is ready & need to place inside the lab.Movement of MachinesNeed to create a process to move the machine from Ground floor storage or lab to 5th Floor lab.

Create water connection (Hot & Cold), Water draining ( Ground Level & 1 meter height). Repair the current valve threads & Use cap to close unsed valves.

Remove cupboards which is currently present in top fo the stations, whcih is not accessible currently). Remove wooden piece near station

Move transformer to corner near SQC station 1 - This transformer is currently inside the cupboard . Also move the equipments (120V HV transformer - FP) to the same place. Use shelfs to storage & give output to socket (Station 15,16).

Keep the 2 set of transformers in the corner b/w station 7 & 8. Keep output to station 6 & 7 in CAT LAB. Use shelf to keep it on top of it Equipments

Currently the Transformer which is b/w station 11 &12, move it to corner whcih is unaccessible or create one shelf on top of LAN ROUTER & move it,Just provide output near station 12 in CAT LAB

Leverage of Machine with cross category team in GTEC - Need to define a process to order new machines or use to use the existing machines.

Time Responsibity Currnet state

25/4/2015 Mayur / Arunpartial work - current valve threads repair

TBD Mayur / Arun

TBD Mayur / Arun

TBD Mayur / Arun

TBD Mayur / Arun

TBD Mayur / Arun

TBD Mayur / Arun

TBD Ashiwini / Arun

TBD

TBD Arun / Mayur

TBD

TBD

TBD Mayur / Arun4/5/2015 Mayur / Arun

TBD Mayur / Arun

24/ 04/2015 Nagendra / Arun

20/4/2015 Mayur / Arun

Cross category team /Shaija

Umapathy/ Arun / Rejitha

Arunkumar Ravindran, Rejitha Girish, Ashwini

Bhondve, Chandika Das

Machine is ready. Basic check need to be done before use.

PROBLEM SOLVING A3 REPORT

WHIRLPOOL CORPORATION CONFIDENTIAL

TITLE -Originated: Start Date OF A3

Revised: Last Revised Date

Problem Statement Countermeasures

Approver: Coach: Author:Author Email : adwrtd_kevtyu@whirlpool.com Author Phone: 0049-7181392325 Date: A3 complete date Date: A3 complete date Date: A3 complete date

Program name, Brief problem title

Implementation

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Reflect / Document

Verification and Follow up

Target / Goal

Cause Analysis

- The Standard

- Current Situation

- Discrepancy / extent of the problem

Rationale for picking up the problem (Importance to business activity, goals or values of the organization)

Measurable description of what you want o change; quality, time, cost, quantity

PROBLEM:

Potential causes, theories?

Most likely direct cause:

Why?--> Why?--> Why?--> Why?--> Why?

Root Cause:

WHAT - Action to be taken

WHERE

WHO - Responsible person

WHEN - Time , dates

(Resulting from Cause Analysis)

- Temporary Measure

- Long Term Countermeasures

- Unresolved issues and actions to address them

- How and when will you check effects?

- How and when will you report findings?

- Who will act upon these findings and how?

- Will this issue be incorporated into a design guide?

- Document and standardize

- Prevent reoccurrence

- Educate others

Click here for root cause analysis template

Use Visual Messages

PROBLEM SOLVING A3 REPORT

WHIRLPOOL CORPORATION CONFIDENTIAL

TITLE -Originated: Start Date OF A3

Revised: Last Revised Date

Approver: Coach: Author:Author Email : adwrtd_kevtyu@whirlpool.com Author Phone: 0049-7181392325 Date: A3 complete date Date: A3 complete date Date: A3 complete date

Problem Statement Describe the problem with supporting data, trend etc Countermeasures Create, Analyze and Rank Countermeasures

Program name, brief problem title (Whenever the way work happens is not ideal, or when a goal or objective is not being met, you have a problem (or, if you prefer, a need) - Identify the problem or need, -What we are trying to do / trying to eliminate, - Confirm problem statement with a team

Implementation Create Visual detailed schedule

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Reflect / Document How will you prevent recurrence ?

Verification and Follow up Ok or Not good? how much? Next Steps?

Target / Goal Establish the criteria for selecting a solution

Cause Analysis Understand the physics & find the root cause of the problem

Before a problem can be properly addressed, one must have a firm grasp of the current situation- Observe the work processes first hand, and document one’s observations- What is happening ( data or information of the issue)-What is supposed to happen with respect to the requirements, expectation or specification- Create a diagram that shows how the work is currently done. Any number of formal process charting or mapping tools can be used, but often simple stick figures and arrows will do the trick.- Quantify the magnitude of the problem (e.g., % of customer deliveries that are late, # of stock outs in a month, # of errors reported per quarter, % of work time that is value-added); if possible, represent the data graphically- Avoid conclusions in the problem statement-Rationale for picking up the problem (impact of the issue to business & importance to solve the issue)

Measurable/ Quantifiable target of what is to be achieved -Clarify the system/domain target-Cascade the targets from system to subsystems to modules with allowance for variation-Quantify the target & specify the measurement method and unit of measurement-Document the assumptions Note: Targets can be from specifications but not always -Refer requirement number through DVP -Target should accounts for variation or safety factor -Use benchmarking data but safety requirements takes the precedence -Confirm that the target and problem statement is consistent

Figure out, what the root causes are to the problem or inefficiency. To accomplish this, first make a list of the main problem(s). Next, ask the appropriate “why?” questions until you reach the root cause.Problem- Why ? -->Why?--> Why?-->Why?-->Why? ---> for root causes- Identify and describe the physics behind the cause- Conclude the most likely cause Note : Use appropriate tools eg: cause & effect analysis, Fish Bone diagram, Pareto analysis etc if needed - Take the Subject Matter Expert's opinion - Support the physics with: - hand calculations, basic engineering - simulations, transfer functions to describe the physics and variation - free body diagrams, graphs, sketches ,schematics etc

A well thought-out implementation plan which should include the list of the actions that need to be done, to get the countermeasures in place and to realize target condition- Break down tasks, assign responsibility and target date- Make sure timing meets the needs of all team members & inline with E&T events ,C2C tollgates- Make decision as a team- Plan to mitigate risks – Technical, commercial and timing – to Identify and obtain support or resources – Is a back-up plan required? Input who, what, when, where, how, measures (process & results).Identify and obtain support or resources from others.

Brain storm and devise countermeasures/concepts to eliminate the root cause(s) and to resolve the problem. Countermeasures are the changes to be made to the system/subsystem/module or the work processes to move closer to ideal situation or to become more efficient.-Combine ideas to get to optimal solution-Use Pugh Analysis, tradeoff curves, or other appropriate method to evaluate the concept. -Minimum criteria for Pugh analysis, Quality, Cost, Timing, Target, Manufacturing -Incorporate team input into criteria selection-Consider unintended consequences / other impacts for the selected concept:- Will it adversely affect any of the product attributes (Core performance, Energy, Noise& Vibration, Reliability, Aesthetics, Capacity, Safety & Codes, Craftsmanship, Usability, Installation & Logistics, and Stake holders (Will it affect any of the process partner)- Use understanding of physics and manufacturing process to meet targets.- Finally list all the counter measures and It's evaluation & ranking and clearly highlight decision/direction- High risk alternatives – define contingencies – additional alternatives

Have a follow up plan to check whether the problem is resolved- Decide on the measure(s) to check whether the issues are resolved or improved - Decide how and when to check the results/findings- Decide who will act upon the findings - Check for the consistency of the results (Mfg process capability)- Confirm whether the cause is eliminated

Document and Standardize, Prevent recurrence, Educate others- Transfer critical lessons learned in knowledge documents (FMEA, DVP&R, Specification & design guide)- Communicate your experience - Teach, Share (Weekly meeting, Coach, Lear- Get Sign-off

WHAT - Action to be takenWHEREWHO - Responsible personWHEN - Time , dates

Use Visual Messages

Click here for root cause analysis template