Professional Documents
Culture Documents
Standard Format 1 PDF
Standard Format 1 PDF
In case of spare-part no
replacement
Due to
Why 1
Why 2
Why 3
Why 4
Why 5
(2)
(3)
Deterioration
(4)
Weak Design
(5)
Poor Skill
JH
(Note : Please fill up this form in pencil immediately after m/c is started)
Kaizen Idea and schedule
PM
Design
E&T Skill
Report No.
Section
Date
Line
Section
Manager
Equipment
Occurance
Date & Time
B/D Occurred
Production Code
Repeat
First Time
Date & Time
of Equipment Started
01 Production
Stopped
Production
Stoppage time
HRS
Min
Phenomenon /
Condition
(How repaired, why it occurred and what has to be done in future, Describe as much as
possible)
Cause, action.
Countermeasure
Maintenance
Cost
Opportunity
Loss
Area Code and
Failure Code
Replacement Part
Cost (Rs.)
In-House Man-days
Hrs
Min
Subcontractor
Cost (Rs.)
Mechanical
Electrical
Electronic
Hydraulic
Pneumatic
Lubrication
Coolant
Refrigeration
Instrumentation
Heating
Failure Code
F01 Clogged
F02 Broken
F03 Leak
F04 Lack of lubrication
F05 Abnormal Condition
F06 Irregular Temp.
Failure Code
F09
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
Crack
Bend
Damaged
Tight/Rusty/Jam
Disengaged
Entangled
Deterioration
Dry Solder
PCB Failure
Burnt
Setting Error
Operating Error
Misalignment
Accident
Short Circuit
Open Circuit
Pressure Drop
Blw Off
Failure Code
F29
F30
F31
F32
F33
F34
F35
F36
F37
F38
F39
F40
F41
F42
F43
F44
F45
F46
Poor contact
Poor Insulation
Tripped
Power Failure
Wire broken
Air Lock
Poor Adjustment
Noisy
Low level
Wrong Wiring
Slip
Earthing
M/C Level
F05
F06
F07
F08
Abnormal Condition
Irregular Temp.
Loose
Wear
F45
F46
F47
Example 1
Cylinder Does Not Operate Smoothly
Question
Answer
Cleaning Strainer
Yes
WHY
ANSWER
ACTION
Clean Strainer
Standardise repairs
Example 2
Oil leaks from cylinder rod each time it operates
Question
Answer
Yes
WHY
ANSWER
ACTION
o-ring cut
o-ring changed
scratch removed
chips were scattered and attached measures taken to prevent chips from
to rod
scattering