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Presented By:E&T
Why Why
Benjamin Franklin's 5-Why Analysis: For want of a nail a shoe was lost, for want of a shoe a horse was lost, for want of a horse a rider was lost, for want of a rider an army was lost, for want of an army a battle was lost, for want of a battle the war was lost, for want of the war the kingdom was and all for the want of a little horseshoe nail. lost,
OVERVIEW OF DEFECT/FAILURE
Dr JURAN STATED THE FOLLOWING IN HIS MORDERN QUALITY MANAGEMENT(JUSE) DEFECTS/FAILURES ARE CLASSIFIED INTO : SPORADIC CHRONIC
OVERVIEW OF DEFECT/FAILURE
SPORADIC DEFECT : Undesirable changes that occur in the present state Requiring treatment designed toRestorethe present state (exchange of jigs that have worn off) Thinking that present state should be maintained
OVERVIEW OF DEFECT/FAILURE
CHRONIC Defects Continued undesirable state , REQUIRING Treatment that changes the presentstate and Thinking to break through the current state
Types of Losses
Losses
Sporadic Losses
Chronic Losses
Single cause One of several causes Combination of several causes Frequent Smaller magnitude Difficult to understand
BREAKDOWN CAUSES
NAKANO SAN HAS COMPILED IN HIS PLANNED MAINTENANCE BOOK THE FACTORS FOR FAILURE
3 Insufficient Strength
Stress and strength
Failure : c Time
15
Uncontrolled stress
Neglected deterioration
Insufficient strength
16
Five Factors
1
Five Countermeasures
1
Adequate compliance with basic requirements Compliance with usage requirements Restoration of deteriorated equipment condition Rectification of design weaknesses Improvement of operation and maintenance skills
3 3
5 5
18
Fig.1.6 Procedures to Achieve Zero Failure Failure analysis of stress and strength
1.Abnormal stress that exceeds the equipment strength is applied (Uncontrolled stress) 2.The equipment strength weakness to the extent that it is unable to bear stress during operation (neglected Deterioration) 3.The equipment inherently possesses weaknesses created during design and fabrication of the equipment (insufficient strength)
Five countermeasure to achieve zero failure 1.Adequate compliance with basic requirements 2.Compliance with usage requirements 3.Restoration of deteriorated equipment condition 4.Rectification of design weakness 5.Improvement of operation and maintenance skills Five phases to achieve zero failures
1. Eliminate the causes of accelerated deterioration and carry out restoration and improvement of equipment conditions
Concept level
Approach analysis
2. Extend inherent service-life of the equipment 3. Research natural deterioration process 4. Search for deterioration parameters 5. Implement predictive maintenance
Build the Jishu-Hozen system Seven Steps to Jishu-Hozen 1.Initial cleaning 2.Countermeasures against contamination sources and areas with difficult access 3. Tentative cleaning and oiling standard procedure 4. Total inspection 5. Autonomous inspection 6. Standardisation 7. Autonomous management
Seven steps to Keikaku-Hozen 1.Analysis of present status 2.Restoration and improvement of the deteriorated equipment condition 3. Tentative standard maintenance procedure 4. Overall inspection of quality function 5. Improvement of inspection and maintenance efficiency 6. Execution of predictive maintenance 7. Horizontal replication
Activity level
20
Pursuit of Causes
Use why why analysis Understand equipment mechanism, details of malfunctions and the method of inspection Promote understanding through the so called set of 3 items Broken parts Analysis document and one point lessons
Investigation/Confirmation
Why ?
Investigation/Confirmation
After Countermeasure
Photo
Problem description Final action taken to make the thing OK After countermeasure is problem eliminated
Spots gets shifted during the operation time Electrode alignment corrected Yes
Date and time of the countermeasure WHY why alignment corrected why electrodes are not Co-axial why play observed between key and piston rod why wear of piston and key ANSWER electrodes are not Co-axial play observed between key and piston rod wear of piston and key ACTION TAKEN Alignment Corrected Screw tightened key replaced and piston rod grinded
Why 4 Why 5
natural deterioration
Root cause: natural deterioration Root cause is one of the following five items 1 Poor condition 2 Poor operating condition 3 deterioration 4 week design 5 poor skill JH PM Design E&T
ACTION
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? WHY Why did you replace o-ring Why o-ring out? why rod has scratch o-ring cut rod has scratch chips were scattered and attached to rod Cylinder located within scattering range of chips and rod cover is not plaed Replacing the o-ring Yes ANSWER Answer
ACTION o-ring changed scratch removed measures taken to prevent chips from scattering cyliners position changed and cover fixed standard design and installation
Why chips were attached on rod Why cylinder located within scatterign range of chips and rod cover not replaced defective design and installation
Reason
Action required
Clean strainer
Stop contamination
Standardize repairs
Quality Assurance +
Equipment and environment management
Jishu-Hozen activities
Material Management +
Skill Education and Training
Design check
PM Analysis
Pursue relationship between quality characteristics and material and energy condition / equipment precision / method conditions
Set conditions of equipment not to generate defects Management of conditions not to generate defects (Hinshitsu Hozen) Zero quality defects
Maintenance and management ability training (Ability to find cause system troubles and to quickly and correctly take actions)
JIPM, 1987
Material
Materials Prior-Process machined parts
Method
Machined conditions Work methods Measuring methods
Man
Morale Environment
Standardization
Machining
Machined products
Inspect
Inspection standard
Quality assurance
JIPM, 1987
Measure, adjust
Defects classification
A - Type defect
OK
B - Type defect
OK
C - Type defect
NOT OK
NOT OK
NOT OK
No action by operator
OK
LSL
OK
USL
LSL
OK
USL
LSL
OK
USL
The output is (OK) initially Becomes (NG) Corrective action is taken by operator Becomes (OK) Use Why Why Analysis
The output is (OK) initially Becomes (NG) No action taken by operator Becomes (OK) Use PM Analysis
The output is (NG) initially Action taken by operator Becomes (OK) (setting scrap)
Clarity on the definition of the defect Frequency of occurrence and effect of defects
NOT OK
OK
LSL USL
NOT OK
No action by operator
OK
LSL USL
NOT OK
OK
LSL
OK
USL
1. Problem Phenomena
pho to
INVISTIGATION/ CONFIRMATION
INVISTIGATION/ CONFIRMATION
INVISTIGATION/ CONFIRMATION
INVISTIGATION/ CONFIRMATION LET US DO THIS TILL WE COME TO A LOGICAL SILLIEST WHY- BEYOND WHICH WE CANNOT PROBE- THAT WILL TAKE US TO THE ROOT OF THE PROBLEM After Phot countermeasure o
No provision to adjust
Why ? Fixed type hinge
KAIZEN - SHEET
Brakes Division
Unit ACT
Sub Comm QM
Year
SL. No.
JiPm -TPM
Category: A
Providing
Changing
2000- 01 AU 087
032505
Machine No :
Problem/Present Status :
5 4 4
Rejn Qty
Before improvement:
After improvement:
Kaizen type
Reversible
Ir-reversible
Why
component pulled out
Why
Tennon broken weaker section of the tennon
If reversible updated in Operation Standard / QCPC JH Check Sheet PM Check Sheet Eqpt / fixture Drawing
Scope & plan for Horizontal Deployment
SLNo. M/cNo. Target date Resp. Status
Why Why
Reduced thickness
Why
to avoid fouling with jaws
032507
Oct,00
NKN
completed
Prevention Detection