Once a molding problem has been
identified, use “method” to determine whether the issue is with Man, Mold,
Machine or Material.
The final M in the 5M equation refers
to “Method”. Method is a very broad category that directly applies to man,
mold, machine and material. Method also considers all internal and external
contributors that affect the key measurable of a lean production operation.
Key measurables in plastic
injection consist of production efficiency, scrap and downtime. The primary
goal of lean manufacturing is 100% efficiency, 0% scrap and down time that is
planned, not unplanned. These goals can sometimes seem to be challenging to
achieve, but with proper analysis and approach the end result can be successful
and profitable.
As measurables are recorded, a part
history is developed. It is this historical data that we use to identify
repeating and/or poorly performing variables. It also helps us to scrutinize
what areas of production need improvement.
Once clear identification of a problem
has been accomplished, it is then time to ask the question, “is this problem
directly associated with Man, Mold, Machine or Material?” In some situations,
only one of these will require change. In others, it could be all four that
need correction. By establishing which of these categories need to be
addressed, it becomes easier to develop solutions that will improve our
“method”.
Here is an example of the 5 M method in
use:
A Japanese headlight manufacturer
determined through scrap data that a significant amount of scratches was
appearing on parts already assembled. The cost of this sort of rework is quite
costly… parts already assembled would need to be tore down, replacement lenses
molded and then a second assembly performed to refurbish the part to an
acceptable quality level.
man, mold, machine and material were
all considered to determine when and how the scratches were occurring. After
review of the entire production process from in-mold to assembly, the cause of
the scratches was tracked to two separate problems, both of which were directly
related to “man”. The problems were:
Parts produced were packed into
cardboard for storage. Some scratches were due to operator handling as they
were packed. The boxes were stacked on skids and then transported into
warehouse racking.
When parts were needed, they were
pulled from warehouse and then transported to the assembly area. Some scratches
resulted directly from parts jostling as they were handled by warehouse
personnel.
To eliminate the problem, special carts
were developed made of a soft cloth that allowed for the parts to be packed,
stored and transported to assembly without the threat of scratched product from
packing and transport. What had been a very large problem became non-existent
through proper analysis and methodical approach.
The 5M approach to molding is an
excellent way to clearly identify problems, which is the foundation to any
problem solving event. Full understanding of any problem helps to develop the
most credible solution to the problems presented. Develop, maintain and
regularly review recordable data for measuring production, scrap and downtime
efficiencies. As the level of historical data increases, factors that improve
production are discovered and implemented. That same data also offers insight
into what problems exist. Clearly define the problem, and then review whether
it is directly related to man, mold, machine or material. Remember that it
could be one, several or all four contributing to the situation.
Develop a
solid list of all areas contributing to the problem, and then systematically
define solutions to those issues. Effective solutions require a complete
understanding of the problems being addressed. Utilize all personnel directly
related to the problem to best develop understanding and methods for
correction. Effectively defining problems and solutions is dependent upon the
complete knowledge base of your entire team. As their ability to create and
adapt to change is refined, continuous improvement becomes more enjoyable. Clearly
defined solutions add to the strength of your organization, bringing it one
step closer to world-class manufacturing.