Small Changes, Big Results

Abstract:This article maintains that by merging continued lean enterprise efforts to improve productivity (specifically, incremental improvements in manual work movements) quality can be affected positively and lead to enhanced productivity. The article summarizes the basics of risk priority numbers (RPNs) through simple, basic procedures. The RPN is explained as a key component of the failure mode and effects analysis (FMEA process). The three main uses of the RPN to rank root causes are also explained. Real-life examples at an automotive parts supplier are used to illustrate how improvements to manual work movements can impact the RPNs. The improvements addressed the problems of tangled O-rings, unassembled locking rings and locking screws, and an ungreased grease …

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