WHY - WHY ANALYSIS SHEET

Breakdown, physical phenomenon

What is your final action? Describe Countermeasure In case of spare-part replacement

In case of spare-part no replacement

Why did you take above action

Due to

Why 1

Why 2

Why 3

Why 4

Why 5 JH PM Design E&T Skill

* Root cause is one of the following 5 items (1) (2) (3) (4) (5) Poor basic Condition Poor operating Condition Deterioration Weak Design Poor Skill

(Note : Please fill up this form in pencil immediately after m/c is started) Kaizen Idea and schedule

BREAKDOWN MAINTENANCE REPORT

Department Section Line Equipment Occurance Date & Time B/D Occurred Production Code Repeat First Time Date & Time of Equipment Started 01 Production Stopped 02 Production not Stopped Production Stoppage time HRS Min Report No. Date Section Manager Cell Leader Prepared By

(Where and what condition ? illustrate if possible)

Phenomenon / Condition

(How repaired, why it occurred and what has to be done in future, Describe as much as possible)

Cause, action. Countermeasure

Maintenance Cost Opportunity Loss Area Code and Failure Code

Replacement Part Cost (Rs.) (Ton, Kg, Pcs) Area Code

A01 A02 A03 A04 A05 A06 A07 A08 A09 A10 Mechanical Electrical Electronic Hydraulic Pneumatic Lubrication Coolant Refrigeration Instrumentation Heating

In-House Man-days

Hrs Min

Subcontractor Cost (Rs.)

Failure Code
F09 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 Crack Bend Damaged Tight/Rusty/Jam Disengaged Entangled Deterioration Dry Solder PCB Failure Burnt Setting Error Operating Error Misalignment Accident Short Circuit Open Circuit Pressure Drop Blw Off F29 F30 F31 F32 F33 F34 F35 F36 F37 F38 F39 F40 F41 F42 F43 F44 F45 F46

Failure Code
Poor contact Poor Insulation Tripped Power Failure Wire broken Air Lock Poor Adjustment Noisy Low level Wrong Wiring Slip Earthing M/C Level

Failure Code F01 Clogged F02 Broken F03 Leak F04 Lack of lubrication F05 Abnormal Condition F06 Irregular Temp.

F05 F06 F07 F08

Abnormal Condition Irregular Temp. Loose Wear

F25 Pressure Drop F26 Blw Off F28 Program Corrupt

F45 F46 F47

WHY - WHY ANALYSIS

Example 1
Cylinder Does Not Operate Smoothly Question What is Your Final Action After Cleaning Strainer, Is it OK WHY Why did you clean strainer Cleaning Strainer Yes ANSWER Strainer was clogged Clean Strainer ACTION Answer

Why Strainer was Clogged

Oil was Dirty

Drain Oil and Clean

Why Oil was Dirty

Dirt entered the tank

Prevent Scattering of chips and cutting fluid

Why does dirt get in

Upper plate of tank has hole and gap Repair error during maintenance work

Plug hole and gap

Why was hole made

Standardise repairs

Example 2
Oil leaks from cylinder rod each time it operates Question What is Your Final Action After replacing the o-ring is it OK? (no more leak/) WHY Why did you replace o-ring o-ring cut Replacing the o-ring Yes ANSWER o-ring changed ACTION Answer

Why o-ring out?

rod has scratch

scratch removed

why rod has scratch

chips were scattered and attached measures taken to prevent chips from to rod scattering Cylinder located within scattering cyliners position changed and cover fixed range of chips and rod cover is not plaed

Why chips were attached on rod

Why cylinder located within scatterign defective design and installation range of chips and rod cover not replaced

standard design and installation