seminário internacional da associação brasileira de ... · combined cost: $45,000...
TRANSCRIPT
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®Enhancing Problem Solving Capabilities
Seminário Internacional da Associação Brasileira de Manutenção (ABRAMAN)
São Paulo, 29-30 de Junho 2011
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®Enhancing Problem Solving Capabilities
Usando a Análise de Causa Raiz para melhorar o resultado de seu balanço
Chris Eckert PE, CMRPApollo Associated Services, LLC
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®Enhancing Problem Solving Capabilities
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®Enhancing Problem Solving Capabilities
Resumo da Apresentação
1. Como avaliar o resultado de seu balanço?2. Economia Média por ACR/Dados de Valor 3. Como gerar economias significantes
e melhorias?
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®Enhancing Problem Solving Capabilities
Como avaliar o resultado de seu balanço?
Lucro Líquido�Receita menos Despesas
� Sobre o que os acionistas estão
preocupados?
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®Enhancing Problem Solving Capabilities
Como avaliar o resultado de seu balanço?Google Inc. CONSOLIDATED STATEMENTS OF INCOME (In thousands, except per share amounts) Three Months Ended March 31, 2008 2009 (unaudited) Revenues $ 5,186,043 $ 5,508,990 Costs and expenses: Cost of revenues (including stock-based compensation expense of $9,148, $12,537)
2,110,536 2,101,504
Research and development (including stock-based compensation expense of $193,800, $168,561)
673,069 641,643
Sales and marketing (including stock-based compensation expense of $42,576, $59,026)
446,898 433,941
General and administrative (including stock-based compensation expense of $35,255, $37,359)
409,305 448,311
Total costs and expenses 3,639,808 3,625,399 Income from operations 1,546,235 1,883,591 Interest income and other, net 167,343 6,210 Income before income taxes 1,713,578 1,889,801 Provision for income taxes 406,492 466,973 Net income $ 1,307,086 $ 1,422,828
LINHA SUPERIOR
LINHA INFERIOR
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®Enhancing Problem Solving Capabilities
O que é a Linha Inferior?
�Linha Inferior pode ser melhorada pelo:
� Aumentando as Vendas (ou aumentando preços)E/OU
� Reduzindo os custos
�Melhorar a Linha Superior é mais divertido, porém
difícil para maioria de profissionais de M&R
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®Enhancing Problem Solving Capabilities
Dados de Valor de ACR
Caso Aplicação
# de ACR’s em
estudo
Valor Médio de Retorno por
ACR
Custo de análise & soluções
Período de Payback
1 Aperfeiçoamento
Manutenção
65 $75,000/ano $1,500 1 semana
2 Melhoria
Manutenção
30 $17,000/ano $1,800 5 semanas
3 Operação/Manu-
tenção/Segurança/
Qualidade
34 $11,300/ano $2,000 9 semanas
4 Qualidade do
Produto
1 $1.3 Bilhão $29 Milhão 1 semana
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®Enhancing Problem Solving Capabilities
Caso 5- Resultados de ACR“Antes”
2004
“Depois”
2007
% de eventos repetidos >10% <5%
Severidade do evento Elevado Muito
Pequeno
# Incidentes em Qualidade >150 35 in 2007
11 in 2008
Custo Perdas $17 Milhão $1.8 Milhão
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®Enhancing Problem Solving Capabilities
Retorno sobre Investimento
�Na tabela anterior,o ROI (Retorno sobre o
Investimento) variou de 565% to 4,480%
�Um ROI’s médio para ACR consistentes é
de aproximadamente 2,000%
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®Enhancing Problem Solving Capabilities
Como você pode gerar resultados?
A Chave………..� Compromisso com a elaboração de uma ACR formal
� Adotar um pensamento de Contabilidade
� Levante pelo maior numero de informações financeiras relacionadas ao evento. � Colete e relate todas as perdas de receita—consulte a Manufatura
� Seja específico para TODAS as perdas monetárias
� P. ex.. “$45,000 custos de reparo”, não “custos de reparo excessivos”
� Um valor estimado é melhor que uma expressão genérica!!
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®Enhancing Problem Solving Capabilities
Relatório formal de ACR
1. Definição do problema com Significância � Valor Financeiro do Problema
� Impacto nos objetivos da organização
2. Diagrama de Causa e Efeito� Causas Ações
� Causas Condições
� 4 fontes de Causas
� Evidências para todas as Causas
EquipamentosProcedimentos
PessoasNatureza
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®Enhancing Problem Solving Capabilities
Relatório formal de ACR
3. 3. Soluções (que ataquem as
causas) com custos estimados.
4. 4. Relatório Formal por escrito.
5. 5. Ações de Monitoramento.
6. 6. Indicadores de Efetividade.
INCIDENT REPORT Purpose: To prevent recurrence, not place blame. Internal Use Only Report Date 7/8/2005 Date Investigation Started: 7/5/2005 Report Number: 2005-123 I. PROBLEM DEFINITION WHAT: Customer Dissatisfaction WHEN: Date: 6/10/03 through 7/14/04 Time: All shifts Relative When: After facility transfer WHERE: Location: Plant 2 Component: Housing Cell: Hand Deburr SIGNIFICANCE: Safety: N/A Revenue: N/A Cost: Rework processing-$2,000/occurrence Customer Service: Customer delay and return-$1,000
concession/occurrence Combined Cost: $45,000 ($3,000/occurrence x 15) Frequency: 15 occurrences II. CAUSE & EFFECT SUMMARY The customer dissatisfaction was caused by us producing and shipping a non-conforming part. We produced the non-conforming part because the chamfer was under the min spec. The chamfer was under min spec because we removed insufficient material and this was a manual operation. Insufficient material was removed because the chamfer was on the wrong side and we applied the standard shop tolerance. The chamfer was on the wrong side because the process instructions were unclear, two different chamfers existed and the employee performed the work at a different facility than normal. The instructions were unclear because the orientation of the part was not defined and the sketch was ambiguous. Two different chamfers existed because of a difference between the drawing spec of 0.02"-0.05" and the standard shop tolerance of 0.005"-0.015". III. SOLUTIONS Causes Corrective Actions Assigned To Due Date two different chamfers existed
Update process drawing to same chamfer both sides
Stan Ford 7/14/2005
sketch ambiguous update sketch to show same chamfer on both sides (0.020-0.050")
Stan Ford 7/14/2005
Procedure does not require
Revise procedure to require validation by seperate inspector
Johnny Walker 7/15/2005
Inspected wrong side Update final inspection sheet
Johnny Walker 7/15/2005
IV. INVESTIGATION TEAM MEMBERS: Johny Walker, Harold Raines, Jen Reily, Stan Ford
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®Enhancing Problem Solving Capabilities
Alavancando os resultados com a ACR para o próximo nível
Aplicação Pró Ativa de uma ACR
Análise Dinâmica com Causas Comuns
�Análise de Causas Sistêmicas
�Casos de ACR de Sucesso
Melhores resultados do que avaliações de ACR individuais.
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®Enhancing Problem Solving Capabilities
Pump 102Down 24
hours
HF is lethal
Not able toRun w/ leak
Seal face cracked
Seal leaking
HF ChemistryCB
Face materialbrittle
Face over-heated
Leak is HF HF in process
EfeitoPrimário
CB
Pressure In pump
Pump randry
Face requires Fluid forcooling
Continues…
Stop
CB = Caused By
CB
CB
CB
CB
CB
CB
ACR Tradicional Reativo
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®Enhancing Problem Solving Capabilities
Pump 102Down 24
hours
HF is lethal
Not able toRun w/ leak
Seal face cracked
Seal leaking
HF ChemistryCB
Face materialbrittle
Face over-heated
Leak is HF HF in process
EfeitoPrimário
CB
Pressure In pump
CB = Caused By
CB
CB
CB
CB
CB
Mill down For 36hours Continues….
EfeitoPrimário
ACR Tradicional Reativo
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®Enhancing Problem Solving Capabilities
Pump 102Down 24
hours
HF is lethal
Not able toRun w/ leak
Seal face cracked
Seal leaking
HF ChemistryCB
Face materialbrittle
Face over-heated
Leak is HF HF in processCB
Pressure In pump
CB = Caused By
CB
CB
CB
CB
CB
Mill down For 36hours Continues….
Novo
Efeito
Primário
ReliabilityLosses in
Akron plant
ACR Dinâmico
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®Enhancing Problem Solving Capabilities
Pump 102Down 24
hours
HF is lethal
Not able toRun w/ leak
Seal face cracked
Seal leaking
HF ChemistryCB
Face materialbrittle
Face over-heated
Leak is HF HF in processCB
Pressure In pump
CB
CB
CB
CB
CB
Mill down For 36hours Continues….
Novo
Efeito
Primário
ReliabilityLosses in
Akron plant Fan 250Down 10
hours
Continues….
ACR Dinâmico
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®Enhancing Problem Solving Capabilities
Pump 102Down 24
hours
Mill down For 36hours
ReliabilityLosses in
Akron plantFan 250Down 10
hours
Cause /Effect
Cause /Effect
Cause /Effect
Cause /Effect
Cause /Effect
Cause /Effect
Cause /Effect Cause /
Effect
Cause /Effect
Cause /Effect
Cause /Effect
??
?
Cause /Effect
A
A
A
B
B
CC
ACR-Dinâmico
Pró ativo!!
CAUSAS COMUNS!
Novo
Efeito
Primário
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®Enhancing Problem Solving Capabilities
Pump 102Down 24
hours
Mill down For 36hours
ReliabilityLosses in
Akron plantFan 250Down 10
hours
Cause /Effect
Cause /Effect
Cause /Effect
Cause /Effect
Cause /Effect
Cause /Effect
Cause /Effect Cause /
Effect
Cause /Effect
Cause /Effect
Cause /Effect
??
?
Cause /Effect
A
A
A
B
B
CC
ACR-Dinâmico
Pró ativo!!Novo
Efeito
Primário
•Grande redução no Efeito Primário!
•Prevenção de Problemas Futuros!
Implementar
Soluções para “A”
ReliabilityLosses in
Akron plant
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®Enhancing Problem Solving Capabilities
Causas Sistêmicas
�Processos de Trabalho
�Cultura
�Práticas Aceitas
�Sistemas de Gerenciamento
�Políticas/Regras
�Valores
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®Enhancing Problem Solving Capabilities
Encontrando Causas Sistêmicas
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®Enhancing Problem Solving Capabilities
Encontrando Causas Sistêmicas
Escopo de Causas
Minutia Restriction•Frequentemente, pessoas param aqui•Escopo de Causas é muito pequeno
Examinando um único caminho causalPerguntando mais“Porques?”,
Escopo das causas
aumentará novamente
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®Enhancing Problem Solving Capabilities
Onde estão as Causas Sistêmicas?
�As causas sistêmicas estão a direita do diagrama de
Causa e Efeito
�Além de onde normalmente paramos de perguntar
“porque?”
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®Enhancing Problem Solving Capabilities
Encontrando Causas Sistêmicas
Aumentando
as Sistêmicas
Causas Sistêmicas
Minutia Restriction
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®Enhancing Problem Solving Capabilities
Falha/Incidente
BBBBB
Causas deLapsos em Medidas de Segurança
XXXXX
CausasTécnicas
AAAAA
EfeitoPrimário
YYYYY
CP = Causado Por
CP
CP
CP
Encontrando Causas Sistêmicas
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®Enhancing Problem Solving Capabilities
RCA - Caso de Sucesso
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®Enhancing Problem Solving Capabilities
Sumário
�ACR irá melhorar a LINHA INFERIOR � ROI 2,000% ROI
� ~$20,000 de economia/ano/RCA
�Uso de método comprovado com relatórios por escrito
�Vá além do ACR reativo� Análise Dinâmica� Causas Sistêmicas
� ACR Pró Ativo
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®Enhancing Problem Solving Capabilities
Dúvidas??
Chris Eckert
Apollo Associated Services, LLC
www.apollorca.com
989-835-3402
800-375-0414