1. Justification
for making wasteful records
Justification for making wasteful records is that you have to record
as evidences of what you asked to do.
Justification for not making wasteful records is that processes you
asked to do have to be as stable as no record for you to confirm is
necessary (refer to 4. No accident resulting in injury or death due
to train crashes of Shinkansen for these forty yeas in
gAgain Toyota
production system in Japan (Jun.3w, 2003)h).@It is the same concept
as g fool proofh.
A person generally has common judgment whether his or her deed
has a substantial meaning. Therefore, if he or she understands a
record is wasteful, he or she cheats the record and it causes demoralization
of the company( refer to g A survey on effectiveness of ISO9000s
for construction sector in Japan: 2001,June,1wh).
2. Meaningless record by checklist before a machine starts
(1) Only memory record of an operator
I saw an operator did check several portion of his automatic machine
before the machine started. He did the checks several items in a
row and when he found nothing wrong, started the machine. And he
came back to his desk and entered check marks to several columns
of the checklist. But if the operator should record the checklist
rightly, he has to have the checklist in hand during his checks
and at each checking step the operator should enter a checkmark
in corresponding column. But to have the checklist in hand is messy
and to enter checkmark at each checking step interrupts the row
of the check operation. Therefore he did not do the right way.
The checklist only shows the operatorfs memory of the checking operations.
(2) Not effective for preventive maintenance
In a factory I saw a checklist which contained check items such
as whether a lamp of the machine lights on when its switch on and
as the next step whether the machine works.
But these items are not for preventive check, because if the lamp
do not light on, corrective maintenances are necessary and the machine
will not move. Therefore, the maintenance records of the machine
are enough and the checklist is meaningless and wasteful one.