Suzuki Powertrain I Ltd Control No- SPIL/MNT/TM/06
5W1H ANALYSIS SHEET Date :
SPIL
LINE TM4
M/C No. TM OP4R
M/C NAME NTC
HOD Maint Advisor Maint Manager Maint Line Incharge Prepared By
REPAIR TIME ANALYSIS
BEFORE ,AFTER CONDITION
PROBLEM :ATC shutter open close problem. S.No Time Activity Status PRESENT CONDITION
Check that supply in the I/O card was not
1 7:00-7:30 NOK Before After
coming.So change the Fuse
Check the cause of shorting physically.Find that a
2 7:30-8:30 NOK
wire in the tower lamp was broken.join the wire.
NO OF OCCURRENCE : 1
Check the cause of shorting physically.Find that a
3 8:30 -9:00
wire in the tower lamp was broken.join the wire.
Run the machine after taking it to home
4 9:00-9:30 Ok
DATE OF OCCURRENCE :06/10/10 position.Now OK
TIME OF OCCURRENCE :7:00 am
LINE STOPPAGE TIME: 140
LOSS OF TRANSMISSION:
ACTION TAKEN : Remove the shorting in limit switch
M/C HAND-OVER To PRODUCTION :9:20 am
ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS
CB/Cp relay faulty OK
Cp/CB TRip Fuse NG
NG
NG
Countermeasure Planned:(PPA)
HORIZONTAL DEPLOYMENT
Shorting in door limit switch S.No. Activity Responsibility Date
Shorting 1
PROBLEM ANALYSIS (WHY -WHY)
STEP 1 2 3 4 5 6
C
o OCCURRENCE CB/CB Fault Wire was lose Wire routing not proper
n
t Shorting in Door Limit Switch
e
n
t
s
o
n
t
e
n
OUT FLOW Shorting in Door Limit Switch Wire routing not proper
t
s Wire was lose
Suzuki Powertrain I Ltd Control No- SPIL/MNT/TM/06
5W1H ANALYSIS SHEET Date :
SPIL
LINE TM2
M/C No. TM OP3R
M/C NAME NTC
HOD Maint Advisor Maint Manager Maint Line Incharge Prepared By
REPAIR TIME ANALYSIS
BEFORE ,AFTER CONDITION
PROBLEM :CP CB trip alarm S.No Time Activity Status PRESENT CONDITION
Check that supply in the I/O card was not
1 7:00-7:30 NOK Before After
coming.So change the Fuse
Check the cause of shorting physically.Find that a
2 7:30-8:30 NOK
wire in the tower lamp was broken.join the wire.
NO OF OCCURRENCE : 1
Check the cause of shorting physically.Find that a
3 8:30 -9:00
wire in the tower lamp was broken.join the wire.
Run the machine after taking it to home
4 9:00-9:30 Ok
DATE OF OCCURRENCE :18/10/10 position.Now OK
TIME OF OCCURRENCE :7:00 am
LINE STOPPAGE TIME: 140
LOSS OF TRANSMISSION:
ACTION TAKEN : Remove the shorting in limit switch
M/C HAND-OVER To PRODUCTION :9:20 am
ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS
CB/Cp relay faulty OK
Cp/CB TRip Fuse NG
NG
NG
Countermeasure Planned:(PPA)
HORIZONTAL DEPLOYMENT
Shorting in door limit switch S.No. Activity Responsibility Date
Shorting 1
PROBLEM ANALYSIS (WHY -WHY)
STEP 1 2 3 4 5 6
C
o OCCURRENCE CB/CB Fault Wire was lose Wire routing not proper
n
t Shorting in Door Limit Switch
e
n
t
s
o
n
t
e
n
OUT FLOW Shorting in Door Limit Switch Wire routing not proper
t
s Wire was lose
Suzuki Powertrain I Ltd Control No- SPIL/MNT/TM/06
5W1H ANALYSIS SHEET Date :
SPIL
LINE TM 1
M/C No. TM113
M/C NAME Washing Machine
HOD Maint Advisor Maint Manager Maint Line Incharge Prepared By
REPAIR TIME ANALYSIS
BEFORE ,AFTER CONDITION
PROBLEM :Washing Machine Home Position error S.No Time Activity Status PRESENT CONDITION
Reset the Alarm.Try to maully operate the machine
1 3:45-4:30 NOK Before After
and do home return
Manually take the robot to the home position and
2 4:30-5:00
tech it there
NO OF OCCURRENCE : 1
Then run the machine Now OK OK
DATE OF OCCURRENCE :13/9/10
TIME OF OCCURRENCE :3:45 pm
LINE STOPPAGE TIME: 75
LOSS OF TRANSMISSION:
ACTION TAKEN : manually take the robot to the home position and do teaching
M/C HAND-OVER To PRODUCTION :5:00 pm
ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS
Robot OK
Robot Fault Controller
OK
NG
Countermeasure Planned:(PPA)
HORIZONTAL DEPLOYMENT
S.No. Activity Responsibility Date
Position Shift
1
Closed
PROBLEM ANALYSIS (WHY -WHY)
STEP 1 2 3 4 5 6
C
o OCCURRENCE Robot Controller Fault Position Shifted Robot not zeroing properly
n
t Robot Not At Home Home Positon
e
n Robot Not At Home Home
OUT FLOW Robot not zeroing properly
t Positon
s Position Shifted
Suzuki Powertrain I Ltd Control No- SPIL/MNT/TM/06
5W1H ANALYSIS SHEET Date :
SPIL
LINE TM 6
M/C No. OP 1l
M/C NAME HOWA
HOD Maint Advisor Maint Manager Maint Line Incharge Prepared By
REPAIR TIME ANALYSIS
BEFORE ,AFTER CONDITION
PROBLEM :Machine Not running in AUTO MODE-Coolant Fault S.No Time Activity Status PRESENT CONDITION
Since no fault was coming in the screen.Try to
1 10:30-11:30 trace the fault bit in the PLC logic.IT was Coming NOK Before After
from the coolant level sensors.
Coolant tank level was low,try to fill the tank but the
2 111:30-12:00
valve was not operating in the auto mode.
NO OF OCCURRENCE : 4
Then temporarily adjust the Level sensor to run the
3 12:00-12:30 OK
machine.
DATE OF OCCURRENCE :4/9/10
TIME OF OCCURRENCE :10:30 am
LINE STOPPAGE TIME: 120
LOSS OF TRANSMISSION:
ACTION TAKEN : Tight the sensor for both low and High Limit
M/C HAND-OVER To PRODUCTION :12:30
ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS
NC unit OK
NC Fault Physical Start Conditions
OK
NG
Countermeasure Planned:(PPA)
HORIZONTAL DEPLOYMENT
S.No. Activity Responsibility Date
Physical Start Conditions Coolant Level
1
To Modify the system by providing
sensors according to the present Dharamveer 30-Oct
contions of the level
PROBLEM ANALYSIS (WHY -WHY)
STEP 1 2 3 4 5 6
C
o Auto mode valve not
OCCURRENCE Coolant Level Low Sensor Tank Not Filling in auto mode
working properly
n
t Physical Level OF Tank Low
e
n Auto mode valve not working
OUT FLOW Physical Level OF Tank Low
t properly
s Tank Not Filling in auto mode
Suzuki Powertrain I Ltd Control No- SPIL/MNT/TM/06
5W1H ANALYSIS SHEET Date :
SPIL
LINE TM4
M/C No. Coolant Tank
M/C NAME
HOD Maint Advisor Maint Manager Maint Line Incharge Prepared By
REPAIR TIME ANALYSIS
BEFORE ,AFTER CONDITION
PROBLEM :Base Coolant fault and Spindle through coolant fault S.No Time Activity Status PRESENT CONDITION
Manually try to sat the valve and run the machines
1 4:00-5:00 NOK Before After
after taking all of them to home.
Open the pump pipeline fittings,pull the pump with
2 5:00-8:00
help of the crane,change the valves.
NO OF OCCURRENCE : 2
Start the coolant system,take all machines to the
3 8:00-9:00 OK
home position and run the machines.Now OK
DATE OF OCCURRENCE :4/9/10
TIME OF OCCURRENCE :4:00 am
LINE STOPPAGE TIME: 300
LOSS OF TRANSMISSION:
ACTION TAKEN : High Pressure coolant Gate valve change
M/C HAND-OVER To PRODUCTION :9:00
ROUTE CAUSE ANALYSIS (FAULT TREE ANALYSIS) COUNTERMEASURE (PERMANENT/TEPMORERY) CONFIRMATION OF EFFECTIVEMNESS
pump OK
base Coolant
Pressure Fault and
Solenoid VAlve
Spindle Coolant OK
FAult
NG
Countermeasure Planned:(PPA)
HORIZONTAL DEPLOYMENT
S.No. Activity Responsibility Date
Manual Gate VAlve Ball OF the VAlve
1
Proper Marking amd regular
Dharamveer
inspection of the valves.
PROBLEM ANALYSIS (WHY -WHY)
STEP 1 2 3 4 5 6
C
o OCCURRENCE Coolant Pressure Fault Manual Valve Faulty Vibration in the systrem
n
t Coolant Not Supplying through Pipeline
e
n Coolant Not Supplying
OUT FLOW Vibration in the systrem Mis Alighnment
t through Pipeline
s Manual Valve Faulty
