p roblem s olving i nnovator team problem solving in a production environment

Problem Solving InnovatorTeam problem solving in a production Environment

FMEA

CAUSE

&

EFFECT

5 WHY

Seal Surface deteriorates

Wrong Washer

Damaged Washer

Washer Hardness

Porous Valve Casting

Seal Distorted

Inclusions in Valve Casting

Casting too Hard (brittle)

Damaged face of valve

Parallelism

Viscosity

Smoothness

Squareness

Adaptor Smoothness

Flatness

Damaged face adaptor

Equipment Breakdown

Adaptor damaged thread

Thread Pitch

Foreign matter

Damaged Thread

Thread Length Bottom

Viscosity of Fluid

Adaptor damaged thread

Thread Size

Incorrect Set-up

Interpretation of extent of Leakage

Loss of Torque on Union

Loss of Torque

Missing Washer

Over Torque in assembly

Test Rig Setting

Fitment damage - test

Pressure Test

Port Test Devt SOPS

Different Operating Conditions

Vibration of Valve

Operational Use

Higher Operating Pressure

Poor Documentation

Incompetent Tech/Engr

RAW MATERIAL MACHINING TAPPING ASSEMBLY/TEST DESIGN/APPLICATION

The Affinity Headings form the 1st Why which gets forwarded to the Fishbone Diagram

Sealing Washer

Valve Body Casting

Thread Adaptor Casting

Receiving Inspection

These Sub-Groups form the 2nd Why which gets forwarded to the Fishbone Diagram

The Contents of these Sub-Groups forms the 3rd Why which gets forwarded to the Fishbone Diagram

2 Root Causes and the Prevention Method for each, forms the 4th Why which gets forwarded to the Fishbone Diagram

Detection and Detection Weakness forms the 5th Why which gets forwarded to the Fishbone Diagram

All this data gets forwarded to the FMEA

5th WHY = Detection & Detection Weakness

1st WHY = Function

2nd WHY = Requirements

3rd WHY = Failure Mode & Failure Effect

4th Why = Root Cause & Prevention Method

The FUNCTION describes each Process Step in a Process

The Process Requirements generally reflect the Operating Conditions that are required for effective Process Control. The Product Requirement generally reflects the Specifications that must be achieved.

The Failure Mode is defined as the manner in which the process could potentially fail to meet the Product or Process Requirements.The Failure Effect is defined as the consequences incurred in the event of an actual Failure.

A Root Cause can be defined as a Product or Process or Design Weakness that may result in a failure.

The Detection Controls are specific actions taken to detect the Failure Mode if it happens.

Watch the FMEA populate instantly

FMEA

Cause & Effect5 Whys

Working Together as One

Problem Solving InnovatorTeam problem solving in a production Environment

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