Root cause analysis

Problem defines: Customers (external and internal) claims ……. Why?

Because there are bad finishing products ……. Why?

1. Coating Damage and scratches (internal customer claim)…….Why?

 Because bad way to handle products From/To truck ………. Why?
 Unskilled workers ………. Why?
 New Workers
 Untrained workers
 There is no cleared handling procedure ………. Why?
 There is no effective QMS
 There are no suitable packaging materials used such as bubble wrap or packing paper ………. Why?
 High cost of suitable packaging materials ………. Why?
 Poor purchasing process ………. Why?
o There is no effective QMS
 Nobody knows about it ………. Why?
 Lack of process improvement ………. Why?
o There is no effective QMS
 Packaging material adhered to the product ………. Why?
 Make Packaging procedure for the products before painting full cure ………. Why?
 The products should be shipped immediately to the site ………. Why?
o Delay in handover process ………. Why?
 High lead time and low process capability ………. Why?
 Nobody measure the actual lead time and capability process
 Erection work in site ………. Why?
 Some products need mechanical and welding process to erect it ………. Why?
 To fix it with other parts (Handrails and accessories) ………. Why?
o Essential processes
 Rubbish and steel parts on the ground in front of erected door, when someone open the door, the
rubbish and steel parts crash into door and then scratch it ………. Why?
 Loading these steel parts in front of erected door ………. Why?
 There is no enough space in the yard
 No warning sign available to prevent the others to put steel parts in front of erected door
2. Undercoat marks appeared in products (External Customer claim) ………. Why?
 Because there is welding works before painting process ………. Why?
 Welding is essential process, but some time undesired defects occurred ………. Why?
 The machine current is high/low ………. Why?
o Unskilled worker………. Why?
 New workers
 Untrained workers
 No work instruction used to prevent unskilled worker to use welding machine
 Unavailable skilled worker (Absentee)
 Rush work
 o Machine malfunction ………. Why?
 No calibration plan ………. Why?
 There is no effective QMS
 Because there is mechanical works before painting process ………. Why?
 To fix the damage in steel that caused by welding process, but during grinding process, the
grinder used by worker may cause damage in the steel (reduce thickness) ………. Why?
 Human error/ unskilled worked
o New workers
o Untrained workers
o No work instruction used to prevent unskilled worker to use the grinder
o Unavailable skilled workers (absentee)
o Rush work
 Steel defects/ marks could not be covered by coating materials in liquid paint ………. Why?
 The solid by volume (SBV) of coating material is low ………. Why?
 Using non suitable primer
 Dry Film Thickness (DFT) is low ………. Why?
o Unskilled workers ………. Why?
 New workers
 Untrained workers
o No cleared procedure available for coating process ………. Why?
 There is no effective QMS
o Wet Film Thickness not used ………. Why?
 Not available in the factory and there is no awareness about using it
o There is no airless machine ………. Why?
 High price cost
 High maintenance cost and time
 Hard to clean it
 It is effective only when we have large amount of parts
o Using high percentage of thinner ………. Why?
 No awareness about using it
o There is no DFT inspection ………. Why?
 There is no awareness about using it
 Steel defects/ marks could not be covered by coating materials in Powder coating ………. Why?
 The DFT for powder coating is low ………. Why?
 No cleared and documented procedure for powder coating ………. Why?
o There is no effective QMS
 There is no suitable filler material used before powder coating ………. Why?
 High cost ………. Why?
o Poor purchasing process ………. Why?
 There is no effective QMS
 Not available in the local market/ or it will take time to find it
 Nobody know about it
 Putty/ filler material roughened applied ………. Why?
 Worker when applied putty, he forgot to make it smooth
 Poor inspection process after putty works ………. Why?
  No enough inspectors available
 Untrained inspector
 Rush work
 There is no effective QMS
 There is no cleared RFI system
3. Variation on color of product (wrong RAL No.), this is only in liquid painting technique ………. Why?
 Wrong in production order ………. Why?
 Human error ………. Why?
 New worker
 Untrained worker
 No cleared customer requirements ………. Why?
 There is no effective QMS
 Bad communication with customers
 No classification system for the specifications of the projects ………. Why?
 There is no effective QMS
 No revised/ review of customer requirements ………. Why?
 There is no effective QMS
 Mistake from painting worker ………. Why?
 He did not notice
 Mistake in receiving painting material process ………. Why?
 There is no cleared documented procedure for receiving materials
 There is no effective QMS
 There is no cleared RFI system
 Poor inspection process after coating process ………. Why?
 No enough inspectors available
 Untrained inspector
 Rush work
 There is no effective QMS
 There is no cleared RFI system
4. Delay in repair works in sites, this is only in powder coating technique (internal claim) ………. Why?
 There is no available touch up material in site ………. Why?
 Powder coating needs only polyurethane (liquid paint) to make touch up ………. Why?
 It is impossible to make touch up by powder coating technique ………. Why?
o It will leave grainy line
 Polyurethane not taken into account in powder coating technique ………. Why?
o The main process required for painting is powder coating so no need to buy liquid
paint.
 Site engineer make sample or take picture for required color, then he go to painting supplier to make
polyurethane with same color of applied powder coating, this process will take long time and may
cause delay in handover to the client ………. Why?
 There is no available polyurethane in site to make touch up.
5. Tack weld on the product (external and internal customer) ………. Why?
 No mechanical works occur to remove tack welds ………. Why?
 The worker did not notice the defects ………. Why?
 Human error
 Poor inspection work ………. Why?
 No enough inspectors available
 Untrained inspector
 Rush work
 There is no effective QMS
 There is no cleared RFI system