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Fisbone diagram tef4 ver1.1

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  • 1. BPS training Robert Bosch VN Welcome to another course in the TPM, Robert Bosch Technical Program, This course covers Basics of Fishbone Diagram1 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 2. BPS training FISHBONE DIAGRAM AND 5 WHY 1) A cause and effect diagram is tool that helps identify, sort, and display possible causes of a specific problem or quality characteristic. It graphically illustrates the relationship between a given outcome and all the factors that influence the outcome. This type of diagram is sometimes called an “Ishikawa diagram” because it was invented by kaoru Ishikawa. 2) The fishbone diagram is a cause‐and‐effect diagram that can be used to identify the potential (or actual) cause(s) for a performance problem. Fishbone diagrams provide a structure for a group’s discussion around the potential causes of the problem.2 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 3. BPS training FISHBONE DIAGRAM AND 5 WHY  Cause-And-Effect Diagram Cause 1 Cause 2 Cause 3 EFFECT Cause 4 Cause 5 Cause 63 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 4. BPS training FISHBONE DIAGRAM AND 5 WHY  What is a cause – and – Effect Diagram?  A Graphic tool that helps identify, sort, and display possible cause of a problem or quality characteristic.4 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 5. BPS training FISHBONE DIAGRAM AND 5 WHY  When should a team use a Cause-And-Effect Diagram ?  Constructing a Cause-And-Effect Diagram can help your team when you need to:  Identify the possible root cause, the basic reason, for a specific effect, problem, or condition.  Sort out and relate some of the interactions among the factors affecting a particular process or effect.  Analyze existing problems so that corrective action can be taken.5 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 6. BPS training FISHBONE DIAGRAM AND 5 WHY  Why should we use a Cause-And-Effect Diagram?  A cause-an-effect diagram is tool that is useful for identifying and organizing the known or possible cause of quality, or the lack of it. The structure provided by the diagram helps team members think in a very systematic way. Some of the benefits of constructing a cause and effect diagram are that it:  Help determine the root cause of a problem or quality characteristic using a structured approach.  Encourages group participation and utilizes group knowledge of the process.6 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 7. BPS training FISHBONE DIAGRAM AND 5 WHY  Uses an orderly, easy to read format to diagram cause and effect relationships.  Indicates possible causes of variation in a process.  Increases knowledge of the process by helping everyone to learn more about the factors at work and how they relate.  Identifies areas where data should be collected for further study.7 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 8. BPS training FISHBONE DIAGRAM AND 5 WHY Benefits of using a Cause-And-Effect Diagram  Help determine root cause  Encourages group participation  Uses an orderly, easy to read format  Indicates possible cause of variation  Increases process knowledge  Identifies areas for collecting data.8 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 9. BPS training FISHBONE DIAGRAM AND 5 WHY How do we develop a cause and effect diagram? 1. Step 1: Identify and define the effect  Decide on the effect to examine  Use operational definitions  Phrase effect as > Positive (an objective) or Negative (a problem)9 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 10. BPS training FISHBONE DIAGRAM AND 5 WHY How do we develop a cause and effect diagram? 2. Step 2: Fill the effect box and draw the spine EFFECT10 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 11. BPS training FISHBONE DIAGRAM AND 5 WHY How do we develop a cause and effect diagram? 3. Step 3: Identify main categories Methods Man Machinery EFFECT Materials Milieu11 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 12. BPS training FISHBONE DIAGRAM AND 5 WHY How do we develop a cause and effect diagram? 2. Step 4: Fill the effect box and draw the spine Methods Man Machinery EFFECT Materials Milieu12 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 13. BPS TPM training Phân tích vẫn đề bằng việc áp dụng phƣơng pháp BIỂU ĐỒ XƢƠNG CÁ VÀ 5 WHY13 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 14. BPS training Eliminating failures through 5Ws (quality tools) From the problem of: “Frequent machine downtime”...1) Why has the machine stopped? “ The fuse has blown due to overload”2) Why is the machine overloaded? “ The spindle drive is not properly lubricated”3) Why is the spindle drive not properly lubricated? “ The oil pump is not working properly”4) Why is not working properly? “ The oil pump axle bearing is worn”5) Why is the oil pump axle bearing worn? “ Dirt has got into the oil pump”6) Why....? ...1st solution • Fit a filter screen on the pump • Plan preventive maintenance14 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 15. BPS TPM training Phân tích vẫn đề bằng việc áp dụng phƣơng pháp BIỂU ĐỒ XƢƠNG CÁ VÀ 5 WHY Measurement Method Man No work Instruction Not enough skill Lack not inspection Spare part Problem : Rotary table NOK Stopper was warn Element Vacuum Rail not unwashed clean Index gear box Belt not ok Pin pusher Netting block Linear bearing Element transfer not Element stuck inside good Milieu Material Machine15 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 16. BPS training Decision Matrix for Potential Causes N Num of Priority Evaluation Score of Team Member Total Potential causes o agreement score Truong Uy Man ThongTien Hoang Trinh Nham Vien Tung 1 Rail not clean 7 8 9 6 10 8 9 8 4 5 5 72 3 Element stuck inside 7 8 9 9 10 8 8 8 5 7 5 77 Element transfer not 2 good 7 10 10 10 9 10 10 10 10 7 8 94 4 belt not ok 7 4 5 6 5 4 5 4 7 4 6 50 5 pin pusher 7 5 5 7 7 5 5 5 7 6 8 60 6 stoper was warn 7 4 5 8 9 5 6 8 8 7 8 68 7 No work instruction 7 7 5 5 6 5 5 5 5 8 7 58 8 Vacuum 7 5 5 6 5 5 4 6 7 6 8 57 9 Linear bearing 3 6 5 4 6 5 4 4 6 8 6 54 10 Nesting block 6 4 5 8 8 5 7 8 8 6 8 67 11 lack of Inspection 1 016 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 17. BPS training Example: Rotary table NOK From the problem of: “Element transfer not good” Why Rotary wrong position? “Rotary Fix wrong” Why rotary Fix wrong? “No standard for technician” Why No standard for technician? “Not standard available” Why...? From the problem of: “Element transfer not good” Why Rail NoK? “ Rail wrong position” Why Rail Wrong position? “Separator breakdown” Why Separator breakdown? “Separator Worn out” Why Separator Worn out? “Separator using Over long life” Why Separator using Over long life? “Spare part not available” Why...?17 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 18. BPS training Example: Rotary table NOK Why Rail NoK? “Element stuck inside” Why Element stuck? “Wrong fixing stopper position’ Why Wrong fixing stopper position? “Skill of technician weak” Why...? Why Element stuck? “Lever Bending” Why Lever Bending?18 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 19. BPS training Example: Rotary table NOK From the problem of: “Element transfer not good” Why Nesting block breakdown? “Vacuum weak or Pin breakdown or Body “ Why Vacuum weak or Pin breakdown or Body? “Dirty or Pin older or Stuck Element” Why Dirty or Pin older or Stuck Element ? “Used Over long life” Why them Used overlong life? “No spare part” Why them no spare part? “Not apply to order list” Why…?19 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 20. BPS training Action Plan Countermeasure Problem Root cause P.I.C Deadline Status (Solution) Rotary table was wrong dont have standard standardize the process Uy 15/01/2012 P position Technicians not enough Rail was wrong skill make training schedule Hung 15/01/2012 P position Technicians not follow daily checksheet make audit schedule Man 15/01/2012 P stopper worn _ Calculate reorder point _ Not order on time T-pusher _ Recheck and make a lever plate _ Not in order list completely order list Man+Uy 30/12/2011 P _ Not have interval _ Define interval for all Vertival slide wearing part Belt20 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
  • 21. BPS training Thank you for your attention ! Question?21 Internal | HcP/TEF Department | 13/07/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.