Copyright © 2009 First Steps Training & Development, Inc. All rights reserved. Copyright © 2008 First Steps Training & Development, Inc. All rights reserved. Trouble Shooting Logic Status Assessment Presented by:

2 Copyright © 2009 First Steps Training & Development, Inc. All rights reserved. 2 Status Assessment Purpose : manage complex issues Core Steps :  Identify Issues  Gather available information / Identify Manageable Elements  Set Priority: examine Impact and Timing / Establish Priority Order  Plan Solution: determine approach & participation required  Track Disposition

33 Status Assessment Purpose : manage complex issues Core Steps :  Identify Issues  Gather available information / Identify Manageable Elements  Set Priority: examine Impact and Timing / Establish Priority Order  Plan Solution: determine approach & participation required  Track Disposition Copyright © 2009 First Steps Training & Development, Inc. All rights reserved.

44 Status Assessment Purpose : manage complex issues Core Steps :  Identify Issues  Gather available information / Identify Manageable Elements  Set Priority: examine Impact and Timing / Establish Priority Order  Plan Solution: determine approach & participation required  Track Disposition Copyright © 2009 First Steps Training & Development, Inc. All rights reserved.

55 Set Priority Identify Issues Identify Manageable Elements ImpactHMLHML TimingHMLHML P ri o ri t y O r d e r Determine Approach Plan ParticipationTrack Disposition Scrap on Line Pair 11 & 12 Capper Jams on Line 11Line efficiency down to 84%, high rework cost MNeed 95% efficiency by June 8 to meet orders H 4 Need to know why, do a DA Need input from Operators, Maintenance, Engineering and Supplier Set up conference call today at 4:00 PM Missed labels on 100 tablet bottle, Line 12 Minimal rework, labels missing on.0037% of bottles LStable, under controlL Drop from list Low count on 100 tablet bottle Line % of bottles, count is 99 to 97, possible fines HMachine certification due on 1 August M 5 B Team has Most Likely Cause. Will try fix tonight B Team, Maintenance Check results with B Team tomorrow by 08:30 Misplaced labels on 250 tablet bottle, Line 12 Excessive rework, labels missing on 0.9% of bottles LIs getting worse rapidlyH 7 Need to know why, do a DA Need input from Operators, Team Leaders and Maintenance Install Unit Load Former (ULF) Line 12 Prepare Line 12 area for ULF Will cause further backlog of orders, possible sale loss MWill require 2 Shifts of down time 15 June M 6 Mostly tasks. Do a verbal PIA with Conversion Team Conversion Team, Northington Maintenance and Engineering Train Line 12 Teams on use of ULF ULF is unique to Newton, no manuals available MTeams must be ready to use 16 June 5:00 AM M 8 Get ULF supplier to provide manuals & training Supplier, Team Leaders Move ULF from Northington and install Part of Northington’s PIA__Provide input to Northington DOIT Conversion Team, Engineering Team Leaders DOIT at scheduled PIA session next Tuesday at 10:00 Choose replacement for retiring Team Coach Many new team members need coaches support MNeed new coach trained and in place by 1 Oct. L 9 CA on both new coach and training track Personnel with input from Team Leaders Safety Issues5 near misses last week in the department RI up to 0.9 worst in the company for last 10 years HCorporate Mandate: Get to 0.5 RI IN 90 days H 3 Do multi-cause analysisSafety Committee, people who had near miss Some lock-outs on Line 11 hang up Potential for serious injury or major equipment damage HPM to start tomorrow at 05:00 AM H 2 Need to know why, do a DA Need input from Operators, Maintenance, Engineering and the possibly the Supplier Emergency shut-down break on line 11 slips Potential for serious injury Can only run at ½ speed until it is fixed. HWill have to short ship orders in 3 days if not fixed H 1 Brake band hit by fork truck, needs replacing Maintenance to install when new band arrive. Supplier to hand carry band to us today Status Assessment - A Reality Based Technology to Sort and Prioritize Issues Status Assessment for: Line Pair 11 & 12 Name: Pat Leader Date: 1 June Copyright © 2009 First Steps Training & Development, Inc. All rights reserved.

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