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