How to escalate when the same defect comes back
If the same action did not work, escalate. The third time, do not try the first method again. The count has to be visible.
When the same defect comes back to the press on the same day, the second time needs a different action, and the third time you stop and get someone. Do not repeat the same adjustment that did not work. Count by defect name and by press, and write the count on the handover board.
Why it is judged this way
A doctor blade line is washed the first time and the blade is changed the second time. The third time, do not wash it again. Write that order as a short strip for the three most common defects and stick it on the press. Without an order, every shift starts with a wash, and the defect stays.
What to compare
| What you see | What to call it | What not to do |
|---|---|---|
| The first time follows step one | Normal | Start with a major repair |
| It is still there the second time | Take the next step | Repeat step one |
| It is still there the third time | Stop and get the supervisor | Keep running and mute the alarm |
At job change or when a roll is opened
- Write two escalation steps for the three most common defects.
- The handover board records today’s count.
- At the third time, stop. Do not mute.
