Why-Why Analysis for Machine Breakdown

Problem Statement: The hydraulic pressing machine’s malfunction disrupted the assembly line.

1. Why: The machine stopped because the motor wasn’t running.
2. Why: The motor stopped because it overheated and triggered a safety shut-off.
3. Why: It overheated due to not enough lubrication.
4. Why: The lubrication system failed because the oil pump wasn’t working properly
5. Why: The pump failed because its filter was clogged and wasn’t cleaned regularly

Root Causes: The pump failed because its filter was clogged and wasn’t cleaned regularly

Evidence/Data/Fact:

1. Machine logs show temperature spikes before the failure.
2. Maintenance records indicate the oil filter was overdue for replacement.
3. Inspection found a clogged filter and insufficient lubrication.

Solution Idea

1. Maintenance Schedule: Set up regular checks and replacements for oil filters.
2. System Upgrade: Invest in a better oil pump and filter system.
3. Monitoring: Add temperature sensors to catch overheating early.

Corrective Action

1. Schedule Implementation: Create and follow a maintenance calendar for oil filter replacements.
2. Training: Train maintenance staff on proper lubrication care and importance of timely replacements.
3. System Upgrade: Buy and install higher-quality oil pumps and filters.
4. Sensor Installation: Install temperature sensors to alert of potential overheating issues.

Preventive Measures

1. Documentation: Use a maintenance checklist and ensure it’s followed.
2. Audits: Conduct regular checks to make sure maintenance schedules are being followed.
3. Supplier Review: Choose reliable suppliers for oil pumps and filters.

Read also:

• FMEA in Pharmaceutical Industry
• 25 Tips on CAPA in Pharmaceutical Industry

Resource Person: Poonath Sekar