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