Breakdown analysis

Step 1. 5W+1H and Phenomenon Summary

Start your Breakdown analysis by answering six simple questions: 5 whys and 1 how

5W+1H
Description
Example

What
What happened? What is the problem?
Mix is not being dispensed from feeder tank

Where
Where did you see the problem? (Production Line, Machine and Location)
Line X feeder tank

Which
Which trend (or pattern) did you see? (Recurring or Sporadic)
Recurring (3rd time in 1 year)

When
When did the problem occur? (Changeover, normal operation, PM or start-up)
Normal operation

Who
Is the problem related to skill? (Either skill dependent or skill independent)
Skill independent

How
How is state changed from normal?
Paddle is not turning

Phenomenon Summary



Use all answers from 5W+1H to construct description of the issue

(HOW+WHAT+WHERE+WHEN+WHICH+WHO)

The paddle isn’t turning and mix is not being dispensed from feeder in Line X feeder tank in downfeed during normal operation, it’s recurring (it has happened 3 times in 1 year) and was skill independent.

Step 2. Why-why analysis

Why
Answer

Why (The paddle isn’t turning and mix is not being dispensed from feeder in Line X feeder tank in downfeed during normal operation, it’s recurring (it has happened 3 times in 1 year) and was skill independent)
Gearbox was seized

Why (Gearbox was seized)?
Lubrication failure

Why (Lubrication failure)?
Mix had contaminated gearbox oil

Why (Mix had contaminated gearbox oil)?
Mix was spilling on top of the seal of gearbox

Why (Mix was spilling on top of the seal of gearbox)?
Mix feeder design allows mix to leak onto gearbox – design flaw



Step 3. Major code

Major Code
Description

Mech
Mechanical

Elec
Electrical

Oper
Operational

Compound
Compound, Mechanical, Electrical or other

Hydr
Hydraulic

Pneum
Pneumatic

Fasten
Fasteners

Step 4. Breakdown Reason

Immediate Actions Taken

Description
Example

What did you do immediately to put it back to operating condition
Cleared mix spillage and replaced gearbox

Step 5. Countermeasures



Countermeasure
Description
Example

Immediate
What can you do right now to prevent recurrence of the breakdown
Replace with “sealed” gearbox to prevent future mix contamination

Intermediate
Is there a better solution to reduce loss?
Replace gearbox oil every 60 days

Long term
What is solution to eliminate future re-occurrences?
Design and install new seal in all tanks

Visual indicator
Can we use visual indicator to detect issue? Anything we can actively do to show the abnormality before it happens?

Breakdown Analysis Template

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