Blog

What I know from the floor, written so you can use it on Monday

One article per tool, with the mistake I see most often and how to fix it. No loose theory.

Root cause analysis: the evidence I ask for first

"I think it was the material," somebody says, with the confidence of a person who has seen it before. Nobody asked for the lot certificate.

Three whys in, and the whiteboard already has a name on it. That name marks the exact point where the team stopped asking.

The PFMEA passed the audit. Two hundred lines, every action closed. And scrap is exactly where it was a year ago.

The operator is in hour eight and the part goes in backwards once in a while. Retraining will not fix it. A stop block will.

The area was spotless for the customer visit. Three months later nobody can find the torque wrench. What was missing fits in five minutes.

Twelve branches filled in and not one proven cause. That is how most of them end, and the defect comes back next month wearing a different name.

Next step

Tell me the concrete problem. I will tell you whether it is mine to solve or someone else’s, and what I would do first.