The document discusses a problem with gauges used to measure t-mold height in thousandths of an inch. Operators struggle to read the gauges, leading to potential out-of-tolerance product shipments. Through a 5-why analysis, it is determined that one gauge reads in reverse, requiring mathematical calculations. The proposed solution is to modify the gauges with green and red wedges to easily indicate measurements within or out of tolerance. Matthew Larson will facilitate training and Kyle Groters will modify the gauges. The target is to have gauges read perfectly and less experienced operators appreciate the ease of use.

1. What is the actual condition? (current state)
What is the Next Target Step?
Should This Be Considered For A Poka-Yoke? YES X NO
Actual Date Completed: 5/19/2014
Zone Leader: Zone:
Starting Date: Target Completion Date:
What is Your Vision:
What Problem Are You Trying To Solve and WHY? (Remember to include what issues the problem is CAUSING)
Use the 5 why methodology to better describe current state
PLAN - Implement the Change VERIFY Success, & Adjust as Needed
Who is doing what, and when might it be completed? Verify Results - What were your conclusions?
1. Why is this problem occurring? The gauges we use are
confusing and new operators struggle to read them
proficiently.
2. Why is that? one of the gauges reads in reverse so they
must do mathematical calculations of thousandths of an
inch.
3. Why is that? t-mold height is measured for tolerance by
thousandths of an inch.
4. Why is that?
5. Why is that?
List Possible Solution(s) -
modify./poka-yoke the gauges to show tolerance
parameters with color.
GRL received a QMN with regard to the installation of t-molding and its height above the
laminate work surface. The gauges we use are hard to read and convert thousands of an inch.
This causes operators to use tribal knowledge when gauging tolerance of t-mold height and
product may be shipped out of tolerance to the customer.
The 2 gauges we use in GRL are inconsistent and
read differently. one reads backwards and math
must be done to convert the reading in line with
the non-cyclical CSW.
Modify the gauges with a green pie wedge for
height within tolerance and red for any reading out
of tolerance.
Matthew Larson will facilitate communications to
Kyle Groters and operators . He will also facilitate
training in reading the gauges for t-mold height.
Kyle Groters will facilitate the modification to the
above mentioned gauges.
Gauges read perfectly and the less experienced
operators appreciate the ease of gauging
tolerance.
Matthew Larson GRL
05/05/2014 05/16/2014
Zero customer complaints