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Appendix 1: SSA “Missing part” Root Causes Analysis Using Fishbone Chart
Receiving Section
Issue Section
Storage Section
Misplace Putaway/Pick TOs.
Failed to write
5XXXXXXXXXX on parts
Fake missing part:
Dedicated parts
Parts in VL06i, not in bins because
falling out during transporting.
Misplace incoming
MROs.
Put-away to/Pick the wrong
parts to/from the wrong bins.
Parts in the bin
missing paperwork.
Missing parts
in SSA
Unsecured turn-in
paper blown away
during transportation.
Turn in/Shipping
Section.
Stock Control Section
Print out duplicate TOs
in the mornings.
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Appendix 1: SSA “Missing part” Root Causes Using Fishbone Chart Analysis
We can analogize the quality control measures in all Sections to a defense in depth/layered defense.
“Missing parts’ result in two consequences:
1) Parts cannot be put away and Put-away TO cannot be closed and become overdue backlog.
2)Parts cannot be picked to satisfy customers’ demands. Pick TOs cannot be closed and become the overdue backlog.
Receiving Section: First line of defense
Errors
Consequence
Corrective/Short- ErrorTerm Actions
proof/Preventive/Long
Term Actions
Pull out MROs and
Missing MROs on
Research under
Train/daily reminder.
misplaced them
incoming parts
supervisory
Designate area for Work-in-
guidance, locate
Process (WIP) and mark
parts or OIC may
with conspicuous labels
(lunch, end of day)
take a loss if last
resort fails.
Remarks
3
Parts are properly
Untrained Storage
Research under
Train/daily reminder: Parts
Designated areas
processed, but TOs
personnel may
supervisory
without paper are supposed
and redefining
do not print out)
misplace such parts. If
guidance, locate
to be properly researched
parts physical
because Stock
NCOs are absent (sick,
parts, or OIC may
and the temp location
flow are critical
locations are blocked
appointment), the parts
take a loss if last
5xxxxxxxxx should be
to prevent
due to inventory
could be sitting there
resort fails
written on the parts and
Condition Code
/admin block (E.g.,
idle /misplaced
move to Storage Section so
A and Code F/H
Storage can do a bin-to-bin
parts from mixing
for walk-thru)
up.
2)need to designate an area
for such parts to prevent
mixing with other parts
Stock Control Section:
4
Errors
Consequence
Corrective/Short- ErrorTerm Actions
Remarks
proof/Preventive/LongTerm Actions
Print out duplicate
Chain reaction:
Research under
Issue Section print out pick
it happened a
TOs (Put-away/Pick)
Duplicate picked
supervisory
list in SSA (not by the MP
couple times in a
parts flow to Issue
guidance, locate
clerk at MP) and SSA
year, even by
section and find no
parts or OIC may
soldier escort pick up and
experienced
matching record in
take a loss
mark off the list for each
Soldier.
the system. If it is
item picked up-----very time
issued anyway, then
and manpower consuming
this part will be short
in the future
Storage Section:
5
Errors
Consequence
Corrective/Short- Error-proof/Preventive/Long-Term
Term Actions
Actions
misplace
Fail to Put-away
Research under
NCOs develop a tracker to sign in/out
Putaway/Pick TOs
/Pick a part.
supervisory
Put-away/Pick TOs
Chain reaction:
guidance, locate
Failure to put away
parts or OIC may
will cause failure
take a loss
Remarks
to pick to satisfy a
demand, resulting
in Pick backlog
Soldier put away parts The part will be
Research under
-Mark BOH container/drawers/bins
-Repetitive work result
into the wrong bin
unavailable in the
supervisory
with conspicuous large letters
in loss of focus
future
guidance, locate
Ensure Soldier rest well before doing
-Cold/wet weather and
parts or OIC may
put-away/pick
outdoor work cause
take a loss
-Allow Soldiers to take small break
distraction/fatigue/cold
injury in Washington
6
-Offer refreshment such as hot
chocolate from DFAC
-Position supplies close to the BOH to
reduce Soldiers’ moving distance that
introduce possibility of errors.
Soldiers pick the
Wrong parts flow
Research under
wrong parts
to Issue and get
supervisory
issued to customer
guidance, put
if Issue fails to
parts back Storage
catch the error
or OIC may take a
loss if parts can
not be found
Same as above
Same as above
7
Issue Section:
Alamo---last line of defense
Errors
Consequence
Corrective/Short- ErrorTerm Actions
proof/Preventive/LongTerm Actions
Remarks
8
Dedicated parts: not real
VL06i is not cleared daily
Locate parts in the
-Train Soldiers to utilize
Print out all
“missing” parts: parts are
designated
Dedicated Customer
DODAAC for class II,
in VL06i, but not in the
“dedicated”
DODAAC list
IX, VII from GCSS.
regular customer issue
customer bin
-Learn to print all customer
Or ask NCOIC/OIC
DODAAC List from GCSS
for it.
bin
Parts in the bin missing
Research under
Train Storage Soldiers to
Acquire sufficient
paperwork---because
supervisory
spend time in attached
supplies: stapler &
Storage did not secure
guidance, locate
MROs to parts in a secured
staples, packing tapes,
the MROs,
parts or OIC may
way
rubber bands
Same as above
take a loss
Storage did not secure
Individual part fell out and
Research under
-Train Storage Soldiers to
multiple parts on the
become a “orphan” part
supervisory
spend time in securing
same MRO together and
without paper
guidance, locate
multiple parts utilizing
parts fell out during
parts or reproduce
ziplock bags, small boxes
transportation to Issue
paper, or OIC
for small/tiny parts
may take a loss
9
-NCOIC provide sufficient
warehouse supplies
-enforce using pallet-size
plastic bin (NOT wooden
pallet) to transport parts to
prevent parts fall-out
10
Turn-in/Shipping Section:
Errors
Consequence
Corrective/Short- ErrorTerm Actions
Remarks
proof/Preventive/LongTerm Actions
Unsecured turn in paper
Parts without paper cannot Research under
-purchase better supplies to
Print out all
be processed or
supervisory
secure/attach waterproof
DODAAC for class II,
incorrectly processed as
guidance,
paperwork
IX, VII from GCSS.
FOI
locate/reproduce
-train/daily reminder
Or ask OIC for it.
paper
Turn-in personnel did not
Accept the wrong parts
Research under
-Train/daily reminder: do
check NSN, qty
and parts will not be
supervisory
not take shortcut.
accepted by LRC
guidance, reverse
-for repetitive offender,
turn-in and
disciplinary action/transfer
reprocess
out
11
Turn in personnel did not
Accept the wrong turn-in
Research under
Train Soldiers to utilize Tire
utilize tire book for tire
tire
supervisory
book
turn in
guidance, reverse
turn-in, reprocess