Anlisis Porqu

JIPM Ishibashi

All rights reserved JIPM

 5W1H
Clasificar el problema de acuerdo a las 5 Ws 1 H,
explicando caractersticas y tendencias

Problema Who What When Where Which How

Quien Qu Cuando Donde Cmo

All rights reserved JIPM

 Comprender la estructura
Diagrama de definicin de una lampara de mano
Switch Tapa
Cuerpo aislante del patn de contacto resorte

Estuche
Patn de contacto

tapn

Espejo reflector
Lente

Foco

Aisilante
Batera
Tapa del lente

All rights reserved JIPM

 Comprender el principio y las reglas bsicas

Principio
El filamento genera luz debido al calor

Reglas Bsicas Regla principal

Que el filamento reciba una corriente elctrica
adecuada
Regla secundaria)
Que el filamento no est cortado
Que la batera tenga cierto voltaje
Que la resistencia elctrica del circuito sea
baja

All rights reserved JIPM

 Hacer un Anlisis Porqu
El Anlisis Porqu es un mtodo que busca llegar a la causa del problema a
travs de repetirse el cuestionamiento porqu? hasta en 5 ocasiones
aproximadamente.

Por qu Por qu Por qu Por qu

W W W W W Medida

Nivel Nivel Nivel

Unidad Sub-unidad Partes

Fenmeno
de la falla

All rights reserved JIPM

 Hacer un Anlisis Porqu
Una vez identificadas todas las posibles causas mediante el Anlisis
Porqu, se estudia cada una y su relacin con el sitio y el objeto
Problema. Se comienza analizando por el nivel W1. Si existe alguna causa
listada, poner N.G., si no la hubiera, poner un crculo
Causa probable-verificar Causa probable-verificar Causa probable-verificar

Checar

Checar
Checar

W-1 W- W- W-
Problema!

Fenmeno

No requiere
revisin

Verificar los porqus del nivel W-1, y si hay

problema, verificar entonces el W-2. Si no hay
problema, all termina la verificacin.
All rights reserved JIPM
 Formato para el
Anlisis Porqu
Problema
W Resultado Resultado W Resultado W Resultado W Result.

All rights reserved JIPM

 Transport After chucking, the product drops during transport. p187

Phenomenon Why Why Why

After chucking, a Downward force on
the product is stronger The gripping force of The chucking force of
product drops during than the gripping force the hand is too weak. the hand is weak.
transport. of the hand.

Contact surface
between the hand and
hand the product is small.

movable side Downward force on

The product weight
the product is too
increased.
strong.

fixed side bottle

Transport speed of
the product is too fast.
receiving stand

elevator

All rights reserved JIPM

 After chucking, a product drops during transport. p196
Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.

Phenomenon Why Why Why

The bottle was Downward force on
the bottle is stronger The hand gripping The hand is weakly
gripped by the hand than the hand gripping force is too weak. pressed to the bottle.
then dropped. force.

Contact surface
between the hand and
the bottle is small.

All rights reserved JIPM

 After chucking, a product drops during transport.
Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.

Why
Downward force on
the bottle is stronger
than the hand gripping
force.

Downward force on The bottle weight

the bottle is strong. increased.
O
K

All rights reserved JIPM

 After chucking, a product drops during transport.
Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.

Why Why
Contact surface
The bottle was held at The hand was
between the hand and
a slant to the hand. declined.
OK
the bottle is small.

When gripped, the

bottle was declined.

The top head of the The bottle was

bottle is low to the gripped during upward OK
hand. movement.

The bottle was not

raised to the end.

The hand position

was higher than the
Abnormal material
upward moving end of OK
was inserted between
the hand and the
OK the bottle.
bottle.

Rubber with the hand

was hardened.
OK

All rights reserved JIPM

 After chucking, a product drops during transport.
Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.
Why
Why
Clearance between
When gripped, the top end of the The hand was Recurrence
the bottle was bottle and the fixed deviated O
declined. side of the hand was horizontally. K prevention
too large. Why Why Why measures
Clearance
The bottle top between the Make a special use
The bottle was Recurrence
end interfered receiving stand Not exclusive for NG stand. Alternatively,
deviated prevention of the elevator
with the fixed the bottle. improve the
horizontally. measures and the bottle is
side of the hand. receiving stand to be
large.
adequate for the
bottle.
The bottle was
declined on the O
receiving stand. K

Resistance force
was stronger Resistance force
than the upward to the elevator The rod is bent. O
force to the was strong. K
elevator.

Air at the
pressed side O
remains. K

Resistance acts
between an
inside wall of the O
air cylinder and K
the piston.

Elevator upward
moving force is
Piston pressing O
force is weak. K
weak.

All rights reserved JIPM

 Package process The cap head was collapsed at the press-fitting process of the cap.

Phenomenon Why Why

Guide inside the press- The cap was declined excessively.
The cap head is
The cap was pressed at fitting block failed to
collapsed at the press-
the declined state. move the cap
fitting process of the cap.
horizontally. Resistance occurred between the cylindrical section
of the cap head and the press-fitting block guide.

Diameter at the bottom side of the press-fitting

block is smaller than the cap external diameter.

The center of the bottle is deviated horizontally

to the center of the press-fitting block.

The press-fitting block is declined.

The press-fitting block is
declined to the bottle.

The bottle is declined

The press-fitting margin at the cap and the bottle

Note The cap was forcedly Resistance between the was increased.
pressed at stopping in cap and the bottle was
Fully observe collapsed the press-fitting process. strong.
cap head to classify
The cap surface is rough.
phenomenon as shown in
the figure for analysis.
When the state written in Elongation in the circumferential direction of the
the column of cap was insufficient.
phenomenon was not
observed, start to analyze The press-fitting block is lowered excessively.
The cap was pressed
at the step just before over an allowable range.
(that is, cap head was
The cap did not touch the bottom of the
collapsed.) press-fitting block.

Height of the bottle increased.

All rights reserved JIPM

 The cap head is collapsed at the press-fitting process of the cap.
Malfunction description: The cap head is collapsed at the press-fitting process of the cap.

Phenomenon Why
The cap was pressed to the
The cap head is Guide inside the press-fitting
press-fitting block at the
collapsed at the block prevents the cap from
declined state to the press-
press-fitting moving horizontally.
fitting surface of the block.
process of the cap.
(Occurred before
position to apply
the pressure to
the cap at normal
condition.)

press-fitting Star Wheel

block
Bottle

cap
head

Star
wheel The press-fitting block was
Bottle declined to the bottle.

All rights reserved JIPM

 The cap head is collapsed at the press-fitting process of the cap.
Malfunction description: The cap head is collapsed at the press-fitting process of the cap.

Why Why

Guide inside the press-fitting

The cap was declined
block prevents the cap from O
excessively.
moving horizontally. K

Resistance occurred between The cap surface is rough. O

the circumferential part of the K
cap head and the guide of the
press-fitting block.
The cap is scratched. O
K
Inside of the press-fitting block
O
The press-fitting block bottom surface is rough.
K
diameter is too small for the cap O
external diameter. K
The press-fitting block is scratched. O
K

The bottle center is deviated

horizontally from the center of O
the press-fitting block. K

All rights reserved JIPM

 The cap head is collapsed at the press-fitting process of the cap.
Malfunction description: The cap head is collapsed at the press-fitting process of the cap.

Why Why Why

A mounting
The press-
The press- part of the
fitting block is O
fitting block is press-fitting
declined to the
bottle.
declined. block has K
gotten rickety.

Recurrence
prevention
Why Why Why measures
The bottle Radius R of NG
neck touches the bottle neck Rework the
No standard is star wheel
The bottle is partially to the is larger than R of the bottle
specified for fitting to the
declined. neck support R of the star neck is large.
the neck area.
area of the star wheel neck bottle
wheel. support area. standard.
When
fabricating the
star wheel,
specify the
The star wheel standard
was fabricated value and
by referencing then formulate
R of the star
sample bottle
wheel is small. the rule
without NG
reflecting the
referring the
bottle standard. standard.

All rights reserved JIPM

 Product defect not filled into to the specified volume (insufficient filling)

Phenomenon Why Why Why

Did not reach the specified
not filled into to
value before filling process
the specified volume.
(insufficient measurement)

filled to does Flow velocity of is slow. Viscosity of is high.

not reach the specified
value.
Filling pressure is low.

Filling time was short.

failed to fill into Resistance occurs at during filling. Air in is not removed.
to the specified value.

Gas generating (or vapor) is not removed.

solidified at the filling port (or before not

adheres to the filled area)
inside before filling port
and is not removed.

leaks (splashed)
before the filling port (or
at the filling port, etc.)

All rights reserved JIPM

 not filled into to the specified volume (insufficient filling).
Malfunction description: Unfilled area appeared near the gate of mold product.

Phenomenon Why Why Why

Unfilled area appears Measured volume is too little. OK
Resin density near the Filled resin volume itself
near the gate of mold
gate is too small. is too little. Reverse flow occurs in the
product. OK
cylinder.

The gate temperature of OK

The gate is solidified the mold is low.
before filling resin.
Resin temperature is too
OK
low.

Injection speed is too slow. OK

Switch timing from
Resin flows backwards
injection to cooling was
before solidifying the gate.
too quick.
Pressure lowered more
quickly than pressure
OK
reduction in the specified
time.
Why Why
Injection time, if extended,
Specified value of the
causes generation of a
injection time is too short.
burr on the molded
product at the center of
the mold.
Why
Parting surface (mating
surface) in the cavity at
the mold center is
deteriorated.

Why
No standard for mold
repair is specified.

NG

Recurrence prevention measures

Improve the parting surface
(mating surface).
Extend the injection time.
Determine the standard to improve
the mold when a certain amount of
burr is generated at the cavity of
the mold center.
All rights reserved JIPM
 not filled into to the specified volume (insufficient filling).
Malfunction description: Unfilled area appeared near the gate of mold product.

Phenomenon Why Why Why Why

Unfilled area appears Gas volume generated
Gas is retained near the Resin involved gas
near the gate of mold from the resin was too Resin absorbed water. OK
gate. generated from the resin.
product. much.

Resin deteriorated inside

OK
the cylinder.

Originally resin has low

OK
molecular weight.

Air at the spool is moved

Resin involves air. OK
back to the cavity.

Air is leaked more slowly Injection speed is too fast. OK

than filling speed of the
resin in the cavity.

Air is difficult to blow from

OK
the air vent.

All rights reserved JIPM