Mining machines accident problem solving via the Toyota A3 Report

The Aim of the paper is to show the advantages associated with the application of the Toyota A3 Report as a standard method of information exchange. It must be noted that as of today this method has not found widespread application. It deserves better. Using specific examples of accidents involving mining machines, the authors show how a Report is completed hoping that this information will help in the adoption of this system in other enterprises. That may contribute to the solution of many problems of industrial management. This paper will be most useful for operators of mining machines.

The Method consists in presenting material on an А3 sheet of paper, that is required in order to set forth all the information needed to solve a problem. Why the А3 format? A3 is the maximum size of a sheet of paper that can be faxed. Before the emergence of personal computers it was the most common tool of communication between Toyota Motor factories. The above example of application of the Toyota A3 Report contains such crucial sections as maintenance and reliability of mining machines, information on prior research, application of the “5 Why?” method and consideration of the human factor. In the example given in the paper, the report describes the circumstances of the accident involving the SRs 1200 24/4 (G2) excavator, that occurred on April 6, 1995 in the open-pit mine Field D, mining basin Kolubara by the Electric Power Industry of Serbia. The report also includes an estimate of the consequences and analysis of the causes of the accident.

The Findings include the methodological approach to the solution of problems, brief format of information presentation, documentation and registration, so that other people involved in the process can review it; assuring the persons involved can form an idea of the operating procedures and outcome of problem resolution. A common language is provided for communication within the company along with a culture of Lean production. The А3 Report is a training process and foundation for future changes in the manufacturing process management.

Conclusions. The Toyota A3 Report has two primary functions: submission of proposals and reporting on the approved measures per the submitted proposals. It allows strictly defining the problem and proceeding to the measures aimed at improving the situation. The practical application of the Report as part of communication within the company and with suppliers will enable quick and targeted solution of managerial problems. Initially developed in Japan within the Toyota company, the method currently finds wider application in Serbian enterprises and elsewhere.

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