Step 1. 5W+1H and Phenomenon Summary
Start your Breakdown analysis by answering six simple questions: 5 whys and 1 how
What happened? What is the problem?
Mix is not being dispensed from feeder tank
Where did you see the problem? (Production Line, Machine and Location)
Line X feeder tank
Which trend (or pattern) did you see? (Recurring or Sporadic)
Recurring (3rd time in 1 year)
When did the problem occur? (Changeover, normal operation, PM or start-up)
Is the problem related to skill? (Either skill dependent or skill independent)
How is state changed from normal?
Paddle is not turning
Use all answers from 5W+1H to construct description of the issue
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 (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)?
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
Compound, Mechanical, Electrical or other
Immediate Actions Taken
What did you do immediately to put it back to operating condition
Cleared mix spillage and replaced gearbox
Step 5. Countermeasures
What can you do right now to prevent recurrence of the breakdown
Replace with “sealed” gearbox to prevent future mix contamination
Is there a better solution to reduce loss?
Replace gearbox oil every 60 days
What is solution to eliminate future re-occurrences?
Design and install new seal in all tanks
Can we use visual indicator to detect issue? Anything we can actively do to show the abnormality before it happens?
Breakdown Analysis Template