Working with multiple methods

- One of my clients, who works in the automotive industry, had a recurring problems. A robotic welder kept crashing against the piece it was supposed to be welding. The impact would bend the welding tip, causing the machine to make welds in the wrong places. To find the root cause, the team first went out to the production floor to learn the complete process, from setting up the automation, until the finished part was delivered. They walked each step to observe, map the process, and ask the operators questions. Then they drew a fish bone diagram that showed several potential causes of the malfunction. They noted factors such as inadequate operator training, incorrect programming of the machines, the impact of the extreme accumulation of heat on the welding tip, and the incorrect assembly of the tip into the automation. Since the company was not tracking the data of rejects, there was no Pareto analysis, and the…