Thursday, November 19, 2009
Why to analyze breakdown and which format to follow?
Once upon a time, there was a king in Mathura , named Kansa. He was the most outrageous king .every body was too ungratified to stay in his kingdom. Once a voice from heaven foretell that the eighth son of sister Devaki & Basudeva will kill him & save mathura. …………………………………
Horrified Kansa arrested them & kept them in jail .He brutally murdered their seven children but the eighth son, lord Krishna escaped from there with divine help. Later lord Krishna killed Kansa & brought peace in Mathura.
Teacher stopped and asked the students, have you any question about it?
One of them raised his hand. Teacher thought what question can arise within this traditional saga.
He asked “if kansa knew the fact then why he kept Devaki and Basudeva in one cell?”
(Please, I have no intention to heart anybodies believe but it’s a nice story to understand the need of root cause analysis I have ever heard)
Moral of the story is without digging the root cause if anybody wants to take an immediate action, then the killer cause may got escaped .
Rather than taking actions that are merely band-aids, a why-why helps you identify how to really prevent the issue from happening again.
I have seen that without looking for expected outcome almost all are following a common format blindly. Either of WHY-WHY or 5W2H.
5W2H is one of the best format to communicate the problem to management but daily breakdowns should be discussed and analyzed in WHY-WHY format and outcome should be a kaizen or final countermeasure ( Change in JH maintenance sheet or preventive maintenance sheet) to stop it
Just compare the both
a) What (Happened) ?
b) Where (Happened) ?
c) Who (Identified /Responsible)
d) Which (Part)
e) Why (It Happened OR Why it is a problem)?
f) How much (Quantify to understand the severity )
g) How to do (Action plan to stop)
h) When (Time line to execute the action plan )
It's a complete informative sheet to communicate to the management but searching for root cause is absent. So, By 5W2H the objective of breakdown analysis is not getting satisfied and Management hopefully have interest only in actions to stop breakdowns rather than in detail of each breakdown until unless management involvement is require for some particular major breakdowns. Out from TPM, Just see the classic example bellow, It's a mail communication what I got from 350.org (easily communicated the subject matter in 5W)
So, the solution is
…Still a actionable root cause found.
It is a method of questioning that leads to the identification of the root cause(s) of a problem and So, To find root cause and take permanent corrective action, WHY-WHY is best brain storming method. Others are FTA analysis, MFMEA (Before machine design), Parato (for priority setting).
How to conduct WHY-WHY analysis?
I usually follow the format I learnt from Yamaguchi San where to ask to final action and I feel it is easy to go down logically rather than to describe B/D phenomena and ask why it happed.
a) Conduct analysis season imitate after the breakdown got over ( memory will be fresh and so it is easy and less time consuming)
b) Ask why to the final action after which machine gets started (Generally we have several actions in way to make the machine up)
c) Then WHY WHY WHY….
Generally causes of breakdown fall in following five categories and expected final action is-
1. Poor Basic condition – Final action on preventive Maintenance to restore and honor basic condition (JH and Or PM).
2. Poor Operating condition - Final action on Maintenance (JH and Or PM)
3. Deterioration – PM check sheet or frequency is expected to be modify
4. Week Design – Cry for a Kaizen (Brain storming) to rectify the same
5. Skill – Training to enhance skill in same area.
Why why Format and example is available in TPM club India web site and you can download it here.
You will get more other Doc.s to download in there download section.
Posted by Joydeep Chakraborty
This Blog is mainly about my ten years journey to achieve manufacturing excellency through improving machine performance in all TPM aspects and applying LEAN Methodology. My Experience includes Learning from the icon leaders of TPM and LEAN experts. And from failures before to get final success.By sharing these experiences, I hope that you may also get benefit in your journey.