IPS-Inventive Problem SolvingWhy? Some problems are easy to solve because we can see them or see the obvious failure points, but some problems are difficult and without a systematic way of solving the problem, we can end up in a loop of confusion (LOC) and we find ourselves repeating steps that we already traveled. IPS is a combination of all sorts of established problem solving methodology that some of our colleagues already invented/implemented.
What is the current performance?
List of potential causes
ANALYZE
Subsystem-Title Here
Theory of Operation
KPIV-Key Process Input and Output
System Block Diagrams
Electrical Diagram
Pneumatic Diagram
DeviceNet Diagram
MCC-Machine Cycle Chart
Equipment Constants
Parts List
Unit Spec Card
Sensor Cards
ECARD
Related SOP
Related OPLS
Vendor Documents
RCA-Root Cause Analysis
TRIZ Principle Used
IMPROVE
List of possible solutions.
PDSA-Plan Do Study Act (Solution)
Trial Run of Solutions
Results of Trial Run
CONTROL
How the fix is maintained?
Countermeasures
Spread
IPS-Inventive Problem Solving WHY? Some problems are easy to solve because we can see them or see the obvious failure point, but some problems are difficult and without a systematic/methodological way of solving the problem, we can end up in a loop of confusion (LOC) and we find ourselves repeating steps that we already travelled. IPS is SASCMP implementation of all sorts of established problem methodology.
HOW? 1. Create an IPS Document Template for each Subsystems. 2. Select Top20 Subsystems (problematic) 3. Assign owner of each Top 20 Problematic Subsystems. 4. Create KPIV Template on all subsytems. 5. Created ECARD Template on all subsytems. 6. Create Project List of Subsystems IPS 7. Assign subsystems to owners 8. Coach, guide, follow up owners progress
LK- SubsystemsLK Computer System eServerLK Computer System NovaLK Computer System APCLK DeviceNet SystemLK KVM SystemLK Main Power CabinetLK FI RobotLK Wet RobotLK LCWELK HCLULK CROSSLK Head/UPALK PlatenLK Slurry SystemLK Pad ConditionerLK Facilities (CDA, N2, DIW, Vac)LK Running BeamLK MegasonicsLK Cleaner 1LK Cleaner 2LK IPA DryerLK EFEM
Ebara SubsystemsEbara Computer System HMIEbara Computer System NovaEbara Computer System EndpointEbara Devicenet SystemEbara KVM SystemEBara Main Power CabinetEBara PolishingEBara Top Ring ControlEBara DresserEBara Turn TableEBara Load/UnloadEBara Linear TransporterEBara Turn Over 1EBara PusherEBara LifterEBara Transfer RobotEBara Swing TransporterEBara Cleaning Module Main CabinetEBara Turn Over 2EBara Cleaner 1EBara Cleaner 2EBara Cleaner 3EBara Cleaner 4EBara Cleaner Linear Transporter
