5W 1H

WHO ANY VARIATION AMONG THE PEOPLE (OPERATOR ) INVLOVED ?

WHAT ANY VARIATION DUE TO PRODUCTION MATERIAL ( FRAME) ?

ANY VARIATION DUE TO EQUIPEMENT INVOLVED? (NUMBERING HEAD)

WHERE ANY VARIATION DUE TO FIXTURE INVOLVED? (MODEL SETTING)

ANY VARIATION DUE TO TOOL INVOLVED? (STYLUS)

WHEN ANY VARIATION RELATED TO THE TIME OR PERIOD ?

WHICH ARE THER ANY CHARACTERISTIC TREND OVER TIME ?

HOW ANY VARIATION IN CIRCUMSTANCES OF OCCURRENCE?

 ELEMENT ANSWER

X
SPECIFIC FRAME MODEL X
SPECIFIC FRAME LOT X
SPECIFIC FRAME SUPPLIER X
ERING HEAD)

STAR & VICTOR

AFTER LUNCH / TEA TIME X

END OF SHIFT X
START OF SHIFT X
MODEL CHANGEOVER

SYSTEM CORRECTION

( A, B, C TYPE) B TYPE

OCCURING FREQUENTLY OR RARELY FREQUENTLY

OCCURING ABRUPTLY OR GRADUALLY ABRUPTLY

OCCURING CONTINOULSY OR DISCONTINOUSLY DISCONTINOUSLY

OCCURING REGUALR OR IRREGUALR INTERVALS IRREGUALR INTERVALS

 5W 1H

Who

What

Where

When
When

1
0.95
0.9
0.85
0.8
0.75
0.7
0.65

Which
0.6
0.55
0.5
0.45
0.4
0.35
0.3
0.25
0.2
0.15
0.1
0.05
0

Row 1

How
 5W 1H

Any Variation Among The People

Invloved ?

Any Variation Due To Production

Material ?

Any Variation Due To Equipement

Involved?

Any Variation Due To Fixture Involved?

Any Variation Due To Tool Involved?

Any Variation Related To The Time Or

Period ?
Any Variation Related To The Time Or
Period ?

Are Ther Any Characteristic Trend Over

Time ?

Any Variation In Circumstances Of

Occurrence?
 ELEMENT ANSWER

Operator NO

Specific Frame model NO

Specific Frame lot NO
Specific Frame supplier NO

Numbering head YES

Star & Victor YES

Stylus YES

After lunch / tea time NO

End of shift NO
Start of shift NO
Model changeover YES
System paramenter correction YES

No trend
( A, B, C TYPE)
( B Type)

Occuring frequently or rarely Frequently

Occuring abruptly or gradually Abruptly

Occuring continously or
Discontinous
discontinously
occuring at regular or irregualr
Irregular Interv
intervals
OCCURRENCE
1
3
5
8
11
6
5
10
ANSWER
No trend
( B Type)

Frequently

Abruptly

scontinously

gular Intervals
 ABNORMAL
PHENOMENA

NUMBERING
POSITION SHIFTS
FROM CENTRE
LINE
 CONTACT DIAGRAM

Y AXIS STYLUS
MOVEMENT B
LINE

DISLOCATED
C
AXIS

MD25948675E00301 D
X AXIS

NUMBERING
AXIS
A

FRAME Y AXIS
 INTERACTING QUANTITATIVE PHYSICAL
ELEMENTS CHANGE

DISTANCE ( C )
DISTANCE ( C ) BETWEEN
BETWEEN NUMBERING
NUMBERING AXIS (A) &
AXIS (A) &
Y AXIS MOVMENT LINE ( B)
Y AXIS MOVMENT LINE
VARIES ( D )
( B)
 CONSTITUENTS CONDITIONS

STYLUS NOT REACHING THE

NUMBERING AXIS

STYLUS NOT REACHING THE

NUMBERING AXIS
STYLUS NOT REACHING THE
NUMBERING AXIS
PRIMARY 4M ANALYSIS

1. Frame rotates/ moves

while numbering.

2. The stylus slips

3. Stylus housing play

4. Drive motor not rotating

4. Drive motor not rotating

5. Drive belt slips

6. Sliding mechanism jam

7. Home position change

 SECONDARY 4M ANALYSIS

1.1 Frame locating centers wear out.

1.2 Distance between centers is more than frame length

1.3 Hydraulic pressure low

1.4 Seating surface of frame damage

1.5 Frame length variation

2.1 Needle worn out (dia)

2.2 Needle tip worn out

2.3 Frame surface roundness out of spec

2.4 Stylus bush wear out

2.5 Needle stroke is more than 4 mm

2.6 Spring jam

3.1 Mounting thread wear out on carriage bore

3.2 Mounting thread wear out on stylus housing

3.3 Stylus not tightened

4.1 No supply / pulses to motor

4.2 Running RPM higher than rated RPM

4.3 Motor jam

5.1 Belt tension loose

5.2 Drive pulley loose

5.3 Driven pulley loose

5.4 Belt teeth not matching with pulley

5.5 Belt wear out / damaged.

6.1 Guide rod bush wear out & misaligned

6.2 Guide rod mounting loose

6.3 More loading of stylus

6.5 Less lubrication

7.1 Home position sensor not sensing

 ABNORMALITY 1 ABNORMALITY 2

Damage / accident

Hydraulic cylinder movement less

Low hydraulic oil Pump not developing pressure

Manufacturing defect Handling defect

Manufacturing defect

Stroke length more Air pressure high

Stroke length more Air pressure high

Manufacturing defect

Dust entry Stroke length more

Wrong setting of stroke Air pressure high

Broken spring foreign material entry

Incorrect mouting

Incorrect mouting

Less torque applied

Loose conection Cable damage

Incorrect setting Malfunctioning of controller

Belt expanded Tensioner bolt loose

Pulley wear out motor shaft wear

Mouting bolt loose

Incorrect belt used

Dust entry

Dust entry

Less torque applied

Air pressure high Numbering depth more

Not connected to sensor Mouting loose

 ABNORMALITY 3

Frame hardness more

Frame hardness more

Return spring damage

Tensioner bush wear out
 INSPECTION CHECKLIST
Component : Frame
Equipment : Numbering machine
Defect Item : Number shifting
# Part Checkpoint Drawing Inspection method Standard values Measure values Evaluation Action if Abnomal

Stylus point sharpness Visual inspection should be pointed

Stylus spring stiffness

O ring roundness Visual inspection

1 Stylus Stylus bush play

Mouting thread condition Visual inspection No thread damage

Air pressure Pressure gauge inspection 4 ~ 6 kg/cm2

Air hose condition Visual inspection No hard bends / crack

Numbering depth System inpection 4 mm

Body thread Visual inspection No thread damage

2 Stylus carriage

Air fittting damage Visual inspection No air leak

guide rod mouting bolt tightness Torque meter

guide ways alignment Dial gauge 0.050 mm

TIMER P ULLEY

guide ways bush wear out Feeler gauge

A IR INLE T
BUSH (G M)
Y AXIS GUIDE RO D

3 Axis
Y A XIS MOTO R
BELT MTG
BUSH (G M ) SCRE W
X A XIS GU IDE ROD
X A XIS GU IDE
RO D

Home proximity sensor mounting No loseness

Dust on guide rod Visual inspection Clean guide rod

Dent on guide rods Visual inspection No dents

 INSPECTION CHECKLIST
TIMER P ULLEY

Belt tension Tension meter

AIR INLET
BUSH (G M)
Y AXIS MOTO R Y AXIS GUIDE RO D
BELT MTG

BOLT
BUSH (G M )
X AXIS GUIDE ROD
SCREW

X AXIS GUIDE
RO D

Mounting bolt tightness Torque meter

5 Belts
Drive pulley freeness Visual inspection No abrupt movement

Driven pulley mounting tighness Torque meter

Driven pulley bearing freeness Visual inspection No abrupt movement

Hydraulic pressure Pressure gauge inspection 40 - 50 Kg/cm2

6 Hydraulic clamping Clamping cylinder movement Measuring scale

Clamp cone damage Visual inpection No dent / deformation

 INSPECTION CHECKLIST
numbering speed System inspection 15 mm / sec
7 System parameters
Movement speed System inspection 110 mm / sec

Air fitting condition Visual inspection No air leak

8 Solenoid valves
Air hose conditon Visual inspection No air leak
 PM ANALYSIS
Component :
Equipment :
Frame
Numbering machine
ON FRAME NUMBERING MACHINE
Defect Item : Number shifting

Standar
Constituent Evaluatio Standard Evaluatio
Phenomena Physical Analysis Primary 4M analysis d Secondary 4 M Analysis
Conditions n Value n
Value
Frame rotates/ No
moves while Clamping fixture seating wear uneven
OK
numbering. out. wear out /
damage
Clamp force is less
28 - 35 28 - 35 30
than the weight of 30 kg/cm2 Hydraulic pressure is low
kg/cm2 kg/cm2 kg/cm2
frame.
No
Frame seating surface uneven
OK
damage wear out /
damage
Frame rotates
Clamping stroke is Frame cone length less than 180 mm OK
not enough to
Play hold spec
frame

40 mm OK
Clamping cylinder stroke is
40 mm OK
less.
Stroke not
enough

No
uneven
Punching needle wear out OK
wear out /
damage

Needle
Play in needle / bush No play OK
Guide Bush
No
Needle slipping uneven
Brass bush wear out. OK
Due to plslips
The stylus ay Needle wear out /
damage

Needle slipping
Due to play
Numbering The distance
Position [C] between Play between Stylus No Not Ok
shifting from the Y axis [A] body & main housing thread
from center & Numbering Mounting thread wash out. damage
line on both Axis [B]
side varies [D] Should OK
No play OK
A not loose
Home for Y axis
by hand
Stylus not tightened properly.
Shift r t
KE5471F95828 C Guide Bush

MD625 Shift
KE5471F95828
MD625 Numbering axis
No teeth
Needle
Body is loose Belt teeth wear out. OK
Due to play damage
B
Drive belt slips No
OK Idler pulley mounting loose.
slippage
No teeth
Drive gear teeth wear out OK
wear out

Incoming Voltage supply 24 V OK

Should
reach
Motor does not rotate 110 mm 200
upto to NOT OK Axis movment speed
Drive does not by desired angle numberi
/sec mm/sec
reach desired ng axis
position 15 20
Marking spped
mm/sec mm/sec
No burr
Guide bush stuck OK
entry
Free
Slides Jam. Manual
moveme OK Lack of lubrication OK
lub
nt
No burr
Foreign material entry ( Burr ) NOT OK
entry
Should Should
Not starting from start No feedback of home return to
NOT OK NOT OK
home position from axis positioning. home
origin position
 Component : Frame PM ANALYSIS ON FRAME NUMBERING MACHINE
Equipment : Numbering machine
Defect Item : Number shifting

Constituent PRIMARY 4M SECONDARY 4M ABNORMALITY

Phenomena Physical Analysis ABNORMALITY 1 ABNORMALITY 2
Conditions ANALYSIS ANALYSIS 3

1.1 Frame locating centers wear

Damage / accident
out.
1.2 Distance between centers is Hydraulic cylinder movement
more than frame length less
1. Frame rotates/
Pump not developing
moves while 1.3 Hydraulic pressure low Low hydraulic oil
pressure
numbering.
1.4 Seating surface of frame
Manufacturing defect Handling defect
damage

1.5 Frame length variation Manufacturing defect

2.1 Needle worn out (dia) Stroke length more Air pressure high Frame hardness more

2.2 Needle tip worn out Stroke length more Air pressure high Frame hardness more

2.3 Frame surface roundness out of

Manufacturing defect
2. The stylus slips spec

2.4 Stylus bush wear out Dust entry Stroke length more
The distance [C]
Numbering Position shifting Stylus not 2.5 Needle stroke is more than 4
between the Y axis mm
Wrong setting of stroke Air pressure high Return spring damage
from from center line on reaching the
[A] & Numbering Axis 2.6 Spring jam Broken spring foreign material entry
both side numbering axis
[B] varies [D] 3.1 Mounting thread wear out on
carriage bore
Incorrect mouting

3.2 Mounting thread wear out on

3. Stylus housing play Incorrect mouting
stylus housing

3.3 Stylus not tightened Less torque applied

4.1 No supply / pulses to motor Loose conection Cable damage

4. Drive motor not
4.2 Running RPM higher than rated
rotating Incorrect setting Malfunctioning of controller
RPM

4.3 Motor jam

5.1 Belt tension loose Belt expanded Tensioner bolt loose Tensioner bush wear out

Y AXIS A
5.2 Drive pulley loose Pulley wear out motor shaft wear

Frame
r t
C 5. Drive belt slips 5.3 Driven pulley loose Mouting bolt loose
NUMBERING 54864163E03220 B
MAD2 5.4 Belt teeth not matching with
SHIFT RANGE AXIS Incorrect belt used
pulley

D(r≠ t) 5.5 Belt wear out / damaged. Dust entry

6.1 Guide rod bush wear out &

Dust entry
misaligned

6.2 Guide rod mounting loose Less torque applied

6. Sliding mechanism
jam
6.3 More loading of stylus Air pressure high Numbering depth more

6.5 Less lubrication

7. Home position 7.1 Home position sensor not

Not connected to sensor Mouting loose
change sensing