Line: Downtime:

6W 2H Illustrition : WPA, Flow or Diagram Root Cause / Why - Why Analysis

Problem Statement : Is standard/WI/SOP in placed ? If Yes do BDA,
If no create Standard first.
Problem Cause 1st Why 2nd Why 3rd Why 4th Why 5th Why 6th Why 7th Why

What :
What is problematic and what imperfections do you use?

Where:
Where in the process do you see loss occur? Where might
similar problem exist
Which :
Which brands, materials, SKUs or formats have the
problem?
When :
When was the problem first noticed? When does it happen
in the life cycle of the part?
Who :
Who has experienced the problem most often?

Whom :

Which lines, systems, or operations have/have not

experienced the problem

How :
How does the failure occur? What events indicates a
failure/loss mechanism?

How Much :
How often does the loss happen? What is the extend of
damage per loss?

Focus Problem:

Implementation Plan
Material Machine Man
6Ms Root Cause Action Plan In-charge Target Date Status
Man

Machine

Material

Method

Measurement

Mother Nature
Mother
Nature Measurement Method

Attendees: RCA Leader:

Name Department
Line: Extruder Downtime: 4.52hrs

6W 2H Illustrition : WPA, Flow or Diagram Root Cause / Why - Why Analysis

Problem Statement : Is standard/WI/SOP in placed ? If Yes do BDA,
If no create Standard first.
Problem Cause 1st Why 2nd Why 3rd Why 4th Why 5th Why 6th Why 7th Why
M30 Rotary Valve Clogging of kibbles
Operator is
Clogged kibbles Extruder out's High steam
What : accommodated
Kibbles are too condensation (too Scheduled Blowdown
Clogging of kibbles at M30 Rotary moisture is too much water from was not followed
Operator forgot by other task or
wet prioritize other
What is problematic and what imperfections do you use? Valve high Boiler)
trouble
Where: Clogged kibbles Extruder out's Floater water Attained
Dryer Kibbles are too Worn-out (as per
at M30 Rotary moisture is too level/sensor sensor life
Where in the process do you see loss occur? Where might wet service technician)
similar problem exist Valve high malfunction span
Which : Clogged kibbles Increase To hit per hour
MEGA Sales
at M30 Rotary production target
Which brands, materials, SKUs or formats have the requirement
problem? Valve capacity requirement

When : Clogged kibbles Operator forgot SOP in increase

February 25, 2023 Entry point going Scraper is too
at M30 Rotary to adjust the production capacity
When was the problem first noticed? When does it happen to dryer is full low
in the life cycle of the part? Valve scraper was not followed

Who :
Von/Mark
Who has experienced the problem most often?

Whom :
Extrusion Lines/All Kibbles
Which lines, systems, or operations have/have not
experienced the problem

How :
How does the failure occur? What events indicates a
failure/loss mechanism?

How Much :
NZD 15,120
How often does the loss happen? What is the extend of
damage per loss?

Focus Problem:

Implementation Plan
Material Machine Man 5Ms Root Cause Action Plan In-charge Target Date Status
1. For another quotation
(high cost) -proceed to
1. Operator was not able to 1. Install Automatic Blowdown
1. Salvador 1. Open lowest price regardless of
blowdown the Boiler because he is 2. Install additional steam trap at Boiler
Man 2. Salvador 2. Open the quotation
accommodated by another task or Area
3. Operator 3. 09.03.23 2. Waiting for quotation
prioritize other trouble 3. ((Need feedback from operator)
update
3. Open

1. Generate frequencey of interval

Next schedule
1. Worn-out Floater/Level Switch based on floater replacement history Rodel/
Machine of 3rd Party 1. For quotation of floater
Sensor - Attained life span 2. Include from the checklist of the third Salvador
Maintenance
party technician

Material
1. SOP in increase production Extruder
Method (Need feedback from operator) 09.03.23 Open
capacity was not followed Operator
1. Limit optimum throughput of Extruder Extruder
Measurement 1. Sales Requirement 28.02.23 Done
to avoid clogging Operator
Mother
Nature Measurement Method Mother Nature

Attendees:
Salvador
Rodel
Albin