Akira Hososhima, President of Torin Consulting
When a mistake occurs in a manufacturing site, it is often assumed that the cause is a lack of confirmation or carelessness on the part of the worker. However, in reality, many organizational factors may be lurking behind the mistake, such as defects in the work standards themselves, inadequate work training, inadequate management of changes to work standards, and a work environment that makes it difficult for workers to report discomfort or awareness regarding work procedures.
In this report, we propose a system to visualize organizational factors that cause mistakes and clarify management issues by conducting a multifaceted statistical analysis of the survey results. The survey has nine questions about work standards, work training, change management, and awareness transmission, and has five options from strongly agree to neither, nor disagree to strongly disagree. In analyzing the responses, the characteristics of the response distribution are visualized in a mosaic diagram, and differences in responses due to organization, job title, employee category, and years of experience are examined using Pearson's chi-square test and Turkey-Kramer HSD test. Based on the analysis results, problems, issues, and solutions are discussed with managers and supervisors. After measures are implemented by management, a second survey is conducted, and the effectiveness of the measures is measured by determining the changes from the first survey overall and by strata, and new improvement actions are promoted.
