Suzuki Powertrain I Ltd

5W1H ANALYSIS SHEET
LINE M/C No. M/C NAME TM4
TM OP4R

Control No- SPIL/MNT/TM/06
Date : SPIL

NTC REPAIR TIME ANALYSIS HOD Maint BEFORE ,AFTER CONDITION Advisor Maint Manager Maint Line Incharge Prepared By

PROBLEM :ATC shutter open close problem.

S.No

Time

Activity

Status

PRESENT CONDITION

1

7:00-7:30

Check that supply in the I/O card was not coming.So change the Fuse

NOK

Before

After

2 NO OF OCCURRENCE : 1

7:30-8:30

Check the cause of shorting physically.Find that a wire in the tower lamp was broken.join the wire.

NOK

3

8:30 -9:00

Check the cause of shorting physically.Find that a wire in the tower lamp was broken.join the wire. Run the machine position.Now OK after taking it to home

DATE OF OCCURRENCE :06/10/10

4

9:00-9:30

Ok

TIME OF OCCURRENCE :7:00 am

LINE STOPPAGE TIME:

140

LOSS OF TRANSMISSION:

ACTION TAKEN : Remove the shorting in limit switch

M/C HAND-OVER To PRODUCTION :9:20 am ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS

CB/Cp relay faulty

OK

Cp/CB TRip

Fuse NG

NG

NG
Countermeasure Planned:(PPA) HORIZONTAL DEPLOYMENT Responsibility Date

Shorting

Shorting in door limit switch

S.No. 1

Activity

PROBLEM ANALYSIS (WHY -WHY) STEP 1 2 3 4 5 6

C o n t e n t s

OCCURRENCE

CB/CB Fault Shorting in Door Limit Switch

Wire was lose

Wire routing not proper

OUT FLOW

Shorting in Door Limit Switch Wire was lose

Wire routing not proper

Suzuki Powertrain I Ltd 5W1H ANALYSIS SHEET LINE M/C No. M/C NAME TM2 TM OP3R Control No.AFTER CONDITION Advisor Maint Manager Maint Line Incharge Prepared By PROBLEM :CP CB trip alarm S. NOK 3 8:30 -9:00 Check the cause of shorting physically.Now OK after taking it to home DATE OF OCCURRENCE :18/10/10 4 9:00-9:30 Ok TIME OF OCCURRENCE :7:00 am LINE STOPPAGE TIME: 140 LOSS OF TRANSMISSION: ACTION TAKEN : Remove the shorting in limit switch M/C HAND-OVER To PRODUCTION :9:20 am ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS CB/Cp relay faulty OK Cp/CB TRip Fuse NG NG NG Countermeasure Planned:(PPA) HORIZONTAL DEPLOYMENT Responsibility Date Shorting Shorting in door limit switch S.Find that a wire in the tower lamp was broken.join the wire.No Time Activity Status PRESENT CONDITION 1 7:00-7:30 Check that supply in the I/O card was not coming. Run the machine position.Find that a wire in the tower lamp was broken.SPIL/MNT/TM/06 Date : SPIL NTC REPAIR TIME ANALYSIS HOD Maint BEFORE .So change the Fuse NOK Before After 2 NO OF OCCURRENCE : 1 7:30-8:30 Check the cause of shorting physically.No.join the wire. 1 Activity PROBLEM ANALYSIS (WHY -WHY) STEP 1 2 3 4 5 6 C o n t e n t s OCCURRENCE CB/CB Fault Shorting in Door Limit Switch Wire was lose Wire routing not proper OUT FLOW Shorting in Door Limit Switch Wire was lose Wire routing not proper .

No Time Activity Status PRESENT CONDITION 1 3:45-4:30 Reset the Alarm. M/C NAME TM 1 TM113 Control No.Try to maully operate the machine and do home return NOK Before After 2 NO OF OCCURRENCE : 1 4:30-5:00 Manually take the robot to the home position and tech it there Then run the machine Now OK OK DATE OF OCCURRENCE :13/9/10 TIME OF OCCURRENCE :3:45 pm LINE STOPPAGE TIME: 75 LOSS OF TRANSMISSION: ACTION TAKEN : manually take the robot to the home position and do teaching M/C HAND-OVER To PRODUCTION :5:00 pm ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS Robot OK Robot Fault Controller OK NG Countermeasure Planned:(PPA) HORIZONTAL DEPLOYMENT Responsibility Date Position Shift S. 1 Activity Closed PROBLEM ANALYSIS (WHY -WHY) STEP 1 2 3 4 5 6 C o n t e n t s OCCURRENCE Robot Controller Fault Robot Not At Home Home Positon Robot Not At Home Home Positon Position Shifted Position Shifted Robot not zeroing properly OUT FLOW Robot not zeroing properly .AFTER CONDITION Advisor Maint Manager Maint Line Incharge Prepared By PROBLEM :Washing Machine Home Position error S.No.Suzuki Powertrain I Ltd 5W1H ANALYSIS SHEET LINE M/C No.SPIL/MNT/TM/06 Date : SPIL Washing Machine REPAIR TIME ANALYSIS HOD Maint BEFORE .

No.Suzuki Powertrain I Ltd 5W1H ANALYSIS SHEET LINE M/C No.Try to trace the fault bit in the PLC logic.try to fill the tank but the valve was not operating in the auto mode. Status PRESENT CONDITION 1 10:30-11:30 NOK Before After 2 NO OF OCCURRENCE : 4 3 111:30-12:00 12:00-12:30 OK DATE OF OCCURRENCE :4/9/10 TIME OF OCCURRENCE :10:30 am LINE STOPPAGE TIME: 120 LOSS OF TRANSMISSION: ACTION TAKEN : Tight the sensor for both low and High Limit M/C HAND-OVER To PRODUCTION :12:30 ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS NC unit OK NC Fault Physical Start Conditions OK NG Countermeasure Planned:(PPA) HORIZONTAL DEPLOYMENT Responsibility Date Physical Start Conditions Coolant Level S.AFTER CONDITION Advisor Maint Manager Maint Line Incharge Prepared By PROBLEM :Machine Not running in AUTO MODE-Coolant Fault S. M/C NAME TM 6 OP 1l Control No.IT was Coming from the coolant level sensors. Then temporarily adjust the Level sensor to run the machine.SPIL/MNT/TM/06 Date : SPIL HOWA REPAIR TIME ANALYSIS HOD Maint BEFORE . Coolant tank level was low.No Time Activity Since no fault was coming in the screen. 1 Activity To Modify the system by providing sensors according to the present Dharamveer contions of the level 30-Oct PROBLEM ANALYSIS (WHY -WHY) STEP 1 2 3 4 5 Auto mode valve not working properly 6 C o n t e n t s OCCURRENCE Coolant Level Low Sensor Physical Level OF Tank Low Tank Not Filling in auto mode OUT FLOW Physical Level OF Tank Low Tank Not Filling in auto mode Auto mode valve not working properly .

change the valves. M/C NAME REPAIR TIME ANALYSIS HOD Maint BEFORE .Suzuki Powertrain I Ltd 5W1H ANALYSIS SHEET LINE M/C No. NOK Before After 2 NO OF OCCURRENCE : 2 3 5:00-8:00 Open the pump pipeline fittings. 1 Activity Proper Marking amd inspection of the valves.No.Now OK OK 8:00-9:00 DATE OF OCCURRENCE :4/9/10 TIME OF OCCURRENCE :4:00 am LINE STOPPAGE TIME: 300 LOSS OF TRANSMISSION: ACTION TAKEN : High Pressure coolant Gate valve change M/C HAND-OVER To PRODUCTION :9:00 ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS pump OK base Coolant Pressure Fault and Spindle Coolant FAult Solenoid VAlve OK NG Countermeasure Planned:(PPA) HORIZONTAL DEPLOYMENT Responsibility Date Manual Gate VAlve Ball OF the VAlve S.SPIL/MNT/TM/06 Date : SPIL Manager Maint Line Incharge Prepared By 1 4:00-5:00 Manually try to sat the valve and run the machines after taking all of them to home. Start the coolant system.AFTER CONDITION PROBLEM :Base Coolant fault and Spindle through coolant fault S.take all machines to the home position and run the machines.No Time Activity Status PRESENT CONDITION Advisor Maint TM4 Coolant Tank Control No.pull the pump with help of the crane. regular Dharamveer PROBLEM ANALYSIS (WHY -WHY) STEP 1 2 3 4 5 6 C o n t e n t s OCCURRENCE Coolant Pressure Fault Coolant Not Supplying through Pipeline Coolant Not Supplying through Pipeline Manual Valve Faulty Manual Valve Faulty Vibration in the systrem OUT FLOW Vibration in the systrem Mis Alighnment .

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