Zero Defects – Increasing the Troubleshooting Technique on PCBA’s and Electronics Devises.

In kaizen events it is very common to be confused in the main objective of Zero Defects. Many people focus more on how to fill out the forms from their computer and desktop. The formats such as Ishikawa, 5 whys, 8D and others; don’t need to be filling out just as requirement.

Obviously formats helps a lot, however, the most important from my point of view and based on my own experience it is to understand Sangen Shugi,

Genba.

Genbutsu.

Genjitsu.

The consultant in this case should guide the team to touch the product and go discarding possible causes or failure modes that may cause the defect, step by step, until they find the root cause.

The team therefore should be documenting the formats with real information, and this must be handwritten in Genba, with the Real Product with Real Data.

In these examples, you can see how the teams actually inquired, finding, which is outside the standard within the product, drawing and taking pictures of the search process and discard the evidence one to one to be completely convinced. And if possible many teams have also duplicated the defects to understand in more detail the phenomenon of the failure.

After all this process the teams goes to document on electronic the findings to have a proper document and evidence of Problem Solving. 

In the videos below are examples of how to perfect methods of finding the problems (Troubleshooting Techniques) and I think it is a good practice to take a video of our own method.

Many examples are described here, for many it sound obvious but possibly for others it could help especially in the PCBA's and other electronic devices.

I hope this information can help you in your next Kaizen Event.