Exercise Continued - Door Jammed

Day 2

Day 1 has past and you have created your draft Realitychart. You just came out of a morning meeting with the Plant Manager where you shared your Realitychart and the following list of outstanding questions (automatically created and displayed in RealityCharting's Action Item List feature).

Find out why Preventative Maintenance Not Performed
Find out why Bay Door Vibrates
Find out why Replacement Part Not Stocked

The Plant Manager is impressed with your analysis of the problem so far and has asked you to continue the investigation. The Plant Manager has given you their full support and is expecting a comprehensive report with solutions on their desk by the end of the day.

The stakeholders are aware of the significance and have added to your understanding of the problem with the following:

Find out why Preventative Maintenance Not Performed.

Discussion with Maintenance Foreman:

“Well, we’ve gotten pretty good at fixing them when they break and it doesn’t happen all the time. We just decided not to put this activity on the PM schedule. Besides we really didn’t have any history on the door to warrant putting it on the PM schedule.”

Find out why Bay Door Vibrates.

Discussion with Resident Engineer:

“I have been looking into why the door vibrates so much and found that the door is inherently flexible by design – it just doesn’t have enough cross bracing. Also, the main drive sprocket on this unit is the wrong one according to the manufacturer’s Operation and Maintenance manuals. And, oh by the way, they recommend tightening the bracket bolts every month. I don’t have any idea why they put the wrong sprocket on, but it is clearly their problem. This one does not align properly and it sets up a vibration in the drive belt, which then gets transferred into the door.”

Find out why Replacement Part Not Stocked.

Discussion with Shipping Foreman:

“Well, we have confirmed that the new roller brackets have been shipped and they are coming in this morning on UPS. I guess the boss is pretty upset about this problem, huh?”

“I just started going through the Door Maintenance manual to see if I can find a minimum spare parts list. We’ve never set up a spares list for the doors, but you can be assured we will have these brackets in stock from now on.”

Completing your Realitychart

Your analysis will now need to be completed so you can attach solutions to the causes that led to the door jamming. Identifying solutions that address specific causes will allow you to prevent their recurrence and truly "fix" this problem.