5W1H Analysis

Clues
What?

With what product did become

the problem recognized?

When?
When did the problem occur?

Where?
At what place did the problem
begin or continue to exist?

Who?
Is there anyone associated
with the problem or solution?

Which?
Indicators and trends that
identify the problem?

How / How many?

Mechanism of failure and

clarity of frequency of failure?

Material / product no. /

type no.

Example
Bicycle concatenation (chain
link), KF 1623

During / range / shift /

When starting out, the chain

jumped out of its track

Plant / field /
Component / place

At the rear hub/sprocket

Name, which shift?

Seems to be independent of
any particular person

Trends, direction,
key indicators
Mechanism
Frequency

It is unpredictable but has

been repeated
Starting out from a stop
4 x in 3 weeks

Combination:
Combination The bike concatenation KF1623 jumped out of its track.
Repeated 4 x unexpectedly while starting out within the last 3 weeks.

N5W Analysis
1st Why?
Reason

Problem

Reason

Action

Action

2nd Why?

4th Why?

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Reason

Action

Checked and been corrected

3rd Why?

Checked and not functional

5th Why?

Cannot be checked at this time

5W1H Analysis:
?

CLUES

WHAT?

DN 100 & 150 Pipes

WHEN?

During acceleration from slow to socket speed

WHERE?

Casting Machine 1 & 2

WHO?
WHICH?
HOW/HOW
MANY?

Overcurrent and tripped motor

Almost every cycle

N5W Analysis:

PROBLEM

1st WHY

2nd WHY?

Misaligned roller base

Assembly defect

Stuck up bottom roller

Overpressure cooling water

Required mould
rotation speed
does not take
place

Over tightened belts

Over tightened top roller

3rd WHY?

1A

Damaged bearing

No grease

2A

Worn out

Low quality material

2B

Oversupply of water When CM # 1 stopped

Motor / Mould pulleys

3A

Wrong pressure adjust

Defective gauge

3B

Technicians error

No gauge

4A

Stuck up screw

Not greased & covered

4B

Technicians error Not using torque wrench

5A

Wrong adjustment

6A

Defective controller

Parts failure

7A

Worn out carbon brush

Life time

7B

Over tightened reaction rollers Technicians error

Tripped motor

ACTIO
N

Wrong combination

8A

ACTION PLAN
S/N

WHAT

WHO

WHEN

REMARKS

1A

Verify and rectify the misalignment of roller

base

IT / AA

May 05

Ductech

2A

Reactivate the auto-greasing system

IT / RA

02 Mar 05

PO
4500044193

2B

Verify the specs / hardness of bottom rollers

AA /
ZD

16 Feb 05

SOP and train the operators

ZD

16 Feb 05

Done

Separate cooling of CM1 and CM2

ES

May 05

Shutdown

3B

Check and replace water gauge

SB

14 Feb 05

Done

4A

Install new gauge for belt tension

MM

16 Feb 05

4B

To grease and put back the cover of screw

MM

16 Feb 05

5A

Instruct technicians to use torque wrench

IT

16 Feb 05

6A

Marking / gauging of adjustment

IT / AA

16 Feb 05

7A

Check and replace elect. Parts if needed

RA

15 Feb 05

Done

7B

Check and replace brushes

RA

15 Feb 05

Done

IT

16 Feb 05

RA

21 Feb 05

3A

8A

To fix the recommended pulley combinations

Next size