WCM FI Standard
7 WCM Tools
Global Standard
7 WCM Tools
Focused Improvement
WHAT WHEN WHERE WHO SHOULD
IT IS TO USE IT TO USE IT USE IT
It represents the backbone of the During the PLAN phase of a Wherever in the plant we apply All of the white collars and,
plant phase of each and every Standard, Major and Advanced a kaizen different from the progressively, skilled Blue
Standard, Major and Advanced Kaizen. Quick, we expect to find collars, such as team leaders,
Kaizen. It has different phases to evidence of the application of making a Standard, Major or
get through in order to fulfill the all of these tools. Advanced Kaizen.
projects requirements:
• Prioritization
• Target evaluation and setting
• Problem description (Sketches,
5W+1H and Data) 5G Principles
• Root Cause analysis
• Phenomena description with
Sketches
• TWTTP
WHICH IS HOW
THE AIM TO USE IT
The goal is to fulfill the kaizen Starting the project into PLAN
requirements have a clear vision phase, follow the 7WCM tools
of Drivers, Data measurement implementation progressively
and target setting, full applying one (or many according
understanding of Problem and to the complexity of the problem)
phenomenon and a logical and of the tools required at each step,
detailed identification of the root starting from the Prioritization up
causes. to TWTTP.
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7 WCM Tools
Focused Improvement
Content Method of Application
* Losses translated into * QA matrix
money based on * Machine breakdown
cost deployment map
1) Prioritization (Find out important problems) * ABC classification * Safety matrix
* Pareto diagram * Value stream
* Stratification mapping, etc.
2) Systematic, logical and detailed deployment of objectives into
right means and right solutions, and measurement of the
results against the objectives and targets
3) Problem description by means of sketches (sketches help to Seeing is
better understand the problem) believing
An elephant has a long nose, two big ears and a big body.
5W+1H
4) 5W+1H following 5G principles (Grasp the actual situation) Histogram's
Control Chart
Cause and effect diagram
5) Root-cause analysis (To identify true causes) 5 Whys analysis
4M analysis
What is the What is the What is the What is the Poka-Yoke
Problem? phenomenon? solution? solution?
6) Phenomena description with sketches (Drawing sketches
requires better understanding of the phenomena in detail).
Observe carefully what are happening behind the problem.
TWTTP
7) The Way to Teach People (TWTTP identifies Root Cause due Questionnaire is
to Lack of Knowledge or Lack of Skill) part of the HERCA
module 3
7 WCM Tools
Focused Improvement
7WCM Tools represent the
backbone of the plant phase
of each and every Standard,
Major and Advanced Kaizen.
It has different phases to get
through in order to fulfill the
projects requirements:
• Prioritization
• Systematic deployment of
objectives into means and
solutions
• Problem description with
Sketches
• 5W+1H and Data applying 5G
Principles
• Root Cause analysis
• Phenomena description with
Sketches
• TWTTP
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#1 – Prioritization
Focused Improvement
Prioritization
(Find out important problems)
The project starts with a clear driver.
WCM identifies its priorities based on
the Cost Deployment Matrices, QA
Matrix and a set of tools that shows
clearly which is the process point or
issue we should focus on.
Main Tools:
* Losses translated into money based
on cost deployment
* ABC classification
* Pareto diagram
* Stratification
* QA Matrix
* Machine breakdown map
* Safety matrix
* Value stream mapping
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#2 – Systematic, Logical and Detailed
Deployment of Objectives
Focused Improvement
Systematic, logical and detailed
deployment of objectives into right
means and right solutions, and
measurement of the results against the
objectives and targets
Measurement is crucial into
deployment of the activities. It is
important to have a clear vision of the
attackable loss and to breakdown all of
the items in it, following MECE concept.
Based on this it has to be identified a
SMART target, and after the
countermeasures have been applied,
results vs expected goal has to be
measured.
Do not mix objectives with means
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#3 – Problem Description using Sketches
Focused Improvement
Problem description using sketches
(sketches help to better understand the
Badly positioned of the lens :
problem) Component assembling is
wrong causing a dimensional
error during assembly;
Sketching is a tool used in various
steps of the problem solving process to
create a simplified and visual
Incomplete stick :
understanding of problem, The stick which seals lens and
body is not enough causing
phenomenon, root cause and solution. lack of sealing;
It is used to create a common
understanding of what is the problem, Overflowed stick:
Excess in the stick which
and to facilitate speed to action. seals lens and body
causing an esthetic defect
• Visualization requires better
understanding of problem in detail. An elephant has a
• Visualization creates sharing information long nose, two
with the concerned people. big ears and a big
• Visualization of a problem leads to action. body.
• “A well drawn figure is as good as one
thousand words”
• The amount of information a figure has is
equal to that of 8 minutes of speech.
• By showing information by a figure, it can
be expressed vividly, well understood and
easily memorized. Seeing is believing
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#4 – 5W+1H with 5G Principles
Focused Improvement
5W + 1H with the 5G principles
(to understand the current situation)
Histogram, Control Chart
Thanks to 5W+1H we use a logical
analysis in order to guarantee that a
problem or topic under discussion is
analyzed taking a complete view of all
its essential aspects: Who, What,
Where When, Why, How.
With the 5G principles by observing
the actual process or problem at the
actual place where it is occurring, the
problem solver is able to obtain actual
data or facts, which will improve the
chances for a better solution.
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#5 – Root Cause Analysis
Focused Improvement
Root-cause analysis
(To identify true causes)
Starting from evidences of facts and
data coming from the investigation of
the system and the identification of the
extent of our issue(s), always following
the 5G principles, it is possible to go
deeper into the analysis in order to
track back along the causes-effect
chain straight to the root cause(s).
Most common tools for this kind of
analysis are the 4M+1D and 5 WHYs.
Both tools are powerful if used along a
brainstorming, giving highlight and
order to the different paths coming out
of it.
All of the possible causes are verified
on the shop floor: GEMBA GEMBUTSU
GENJITSU steps are crucial to ensure
that the analysis results are consistent.
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#6 – Phenomena Description with Sketches
Focused Improvement
Phenomena description with sketches
(Drawing sketches requires better
understanding of the phenomena in detail).
Observe carefully what are happening behind
the problem.
As described with problem description,
visualization it’s crucial to share the
info tied to the kaizen in a very fast and
effective way.
For the phenomena description it is
particularly important because if we’re
able to draw it then we’re able to fix it.
In fact having the drawings of all of the
active elements of the focused process, What is the What is the What is the What is the Poka-
and using them to describe how the problem? phenomenon?
What is happening?
solution? Yoke solution?
phenomena is generated, we have fully
understanding of the elements that
need to be fixed, and the best way to do
it.
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#7 – The Way To Teach People
Focused Improvement
TWTTP (The Way To Teach People)
is a tool that is used in human error
root cause analysis. The purpose of the
TWTTP is to evaluate, through an
interview process, the level of
knowledge of the operator to find out if
there is a lack of it that might be the
root cause for the human error.
The interview is based on 4 questions:
1. Is it clear how to execute your job
correctly?
2. How can you verify that you are
working correctly?
3. How do you know that you
performed your operation without
any defects?
4. What do you do if you have a
problem?
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