Anlisis Porqu

JIPM Ishibashi

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

Who

What

Quien

Qu

When

Where

Which

How

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Cuando

Donde

Cmo

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

Tapa
resorte
Estuche

tapn

Lente

Espejo reflector

Foco
Aisilante
Tapa del lente

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Batera

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

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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
W

W
Nivel
Unidad

Fenmeno
de la falla

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Por qu

Por qu
W

Nivel
Sub-unidad

W
Nivel
Partes

Por qu
W

Medida

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

W-

W-

Problema!

No requiere
revisin

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W-

Causa probable-verificar
Checar

Fenmeno

Checar

Checar

W-1

Causa probable-verificar

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

problema, verificar entonces el W-2. Si no hay
problema, all termina la verificacin.

Formato para el
Anlisis Porqu
Problema

W
Resultado

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Resultado

Resultado

Resultado

W Resu

Transport

After chucking, the product drops during transport. p187

Phenomenon

Why

Why

After chucking, a
product drops during
transport.

Downward force on
the product is
stronger than the
gripping force of the
hand.

The gripping force of

the hand is too weak.

fixed side

The chucking force of

the hand is weak.

Contact surface
between the hand and
the product is small.

hand

movable side

Why

Downward force on
the product is too
strong.

The product weight

increased.

bottle

receiving stand

elevator

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Transport speed of
the product is too fast.

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

The bottle was

gripped by the hand
then dropped.

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

The hand gripping

force is too weak.

Why
The hand is weakly
pressed to the bottle.

Contact surface
between the hand and
the bottle is small.

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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 is strong.

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The bottle weight

increased.

O
K

After chucking, a product drops during transport.

Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.

Contact surface
between the hand and
the bottle is small.

Why

Why

The bottle was held at

a slant to the hand.

The hand was

declined.

OK

When gripped, the

bottle was declined.

The top head of the

bottle is low to the
hand.

The bottle was

gripped during
upward movement.

OK

The bottle was not

raised to the end.

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Abnormal material
was inserted between
the hand and the
bottle.

OK

Rubber with the hand

was hardened.

OK

The hand position

was higher than the
upward moving end of
the bottle.

OK

After chucking, a product drops during transport.

Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.
Why
When gripped,
the bottle was
declined.

Why

Clearance between
the top end of the
bottle and the fixed
side of the hand was
too large.

The hand was

deviated
horizontally.

The bottle top

end interfered
with the fixed
side of the hand.

The bottle was

declined on the
receiving stand.

Resistance force
was stronger
than the upward
force to the
elevator.

O
K

Why

Why

Why

The bottle was

deviated
horizontally.

Recurrence
prevention
measures

Clearance
between the
receiving stand
of the elevator
and the bottle is
large.

Not exclusive for

the bottle.

Resistance force
to the elevator
was strong.

The rod is bent.

O
K

Air at the
pressed side
remains.

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

Elevator upward
moving force is
weak.

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Piston pressing
force is weak.

O
K

O
K

O
K

O
K

Recurrence
prevention
measures
NG

Make a special use

stand. Alternatively,
improve the receiving
stand to be adequate
for the bottle.

Package process
The cap head is
collapsed at the pressfitting process of the
cap.

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

Phenomenon

Why

The cap was pressed at

the declined state.

Guide inside the pressfitting block failed to

move the cap
horizontally.

Why
The cap was declined excessively.

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 to the bottle.

The press-fitting block is declined.

The bottle is declined

Note
Fully observe collapsed
cap head to classify
phenomenon as shown in
the figure for analysis.
When the state written in
the column of
phenomenon was not
observed, start to analyze
at the step just before
(that is, cap head was
collapsed.)

The cap was forcedly

pressed at stopping in
the press-fitting process.

Resistance between the

cap and the bottle was
strong.

The cap surface is rough.

Elongation in the circumferential direction of the

cap was insufficient.

The cap was pressed

over an allowable range.

The press-fitting block is lowered excessively.

The cap did not touch the bottom of the

press-fitting block.

Height of the bottle increased.

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The press-fitting margin at the cap and the

bottle was increased.

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
The cap head is
collapsed at the
press-fitting
process of the
cap. (Occurred
before position to
apply the pressure
to the cap at
normal condition.)

press-fitting
block

The cap was pressed to the

press-fitting block at the
declined state to the pressfitting surface of the block.

Why
Guide inside the press-fitting
block prevents the cap from
moving horizontally.

Star Wheel
Bottle

cap
head

Bottle

Star
wheel

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The press-fitting block was

declined to the bottle.

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

block prevents the cap from
moving horizontally.

The cap was declined

excessively.

O
K

Resistance occurred between

the circumferential part of the
cap head and the guide of the
press-fitting block.

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The cap surface is rough.

O
K

The cap is scratched.

O
K

Inside of the press-fitting block

surface is rough.

The press-fitting block bottom

diameter is too small for the cap
external diameter.

O
K

The bottle center is deviated

horizontally from the center of
the press-fitting block.

O
K

The press-fitting block is

scratched.

O
K
O
K

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

The pressfitting block is

declined to the
bottle.

The pressfitting block is

declined.

A mounting
part of the
press-fitting
block has
gotten rickety.

O
K

Why

The bottle is
declined.

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The bottle
neck touches
partially to the
neck support
area of the star
wheel.

Radius R of
the bottle neck
is larger than
R of the star
wheel neck
support area.

Why

Recurrence
prevention
measures

Why
NG

R of the bottle
neck is large.

No standard is
specified for
the neck area.

R of the star
wheel is small.

The star wheel

was fabricated
by referencing
sample bottle
without
reflecting the
bottle
standard.

NG

Rework the
star wheel
fitting to the
bottle
standard.
When
fabricating the
star wheel,
specify the
standard value
and then
formulate the
rule referring
the standard.

Product defect

not filled into to the specified volume (insufficient filling)

Phenomenon

Why

not filled into to

the specified volume.

Did not reach the specified

value before filling process
(insufficient measurement)

filled to does
not reach the specified
value.

Why

Flow velocity of is slow.

Why

Viscosity of is high.

Filling pressure is low.

Filling time was short.

failed to fill into

to the specified value.

Resistance occurs at during filling.

Air in is not removed.

Gas generating (or vapor) is not removed.

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

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

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solidified at the filling port (or before not

filled area)

 not filled into to the specified volume (insufficient filling).

Malfunction description: Unfilled area appeared near the gate of mold product.
Phenomenon

Why

Why

Unfilled area appears

near the gate of mold
product.

Resin density near the

gate is too small.

Filled resin volume itself

is too little.

The gate is solidified

before filling resin.

Resin flows backwards

before solidifying the
gate.

Why
Measured volume is too little.

OK

Reverse flow occurs in the

cylinder.

OK

The gate temperature of

the mold is low.

OK

Resin temperature is too

low.

OK

Injection speed is too slow.

OK

Switch timing from

injection to cooling was
too quick.
Pressure lowered more
quickly than pressure
reduction in the specified
time.

Why
Specified value of the
injection time is too short.

OK

Why
Injection time, if extended,
causes generation of a
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

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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.

 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

near the gate of mold
product.

Gas is retained near the

gate.

Resin involved gas

generated from the resin.

Gas volume generated

from the resin was too
much.

Resin absorbed water.

OK

Resin deteriorated inside

the cylinder.

OK

Originally resin has low

molecular weight.

OK

Injection speed is too fast.

OK

Air is difficult to blow from

the air vent.

OK

Resin involves air.

Air at the spool is moved

back to the cavity.

Air is leaked more slowly

than filling speed of the
resin in the cavity.

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OK