Do Variability Analysis and then Plot the Ishikawa Diagram
ANUJ KUMAR SHRIVASTAVA, Manager, India, Premium Member
The best thing you can do is try doing a Variability Analysis
. This a best practice technique for finding out the root cause. By performing a VA, you will find out the causes, say:
- Improper use of machine
- Heavy loads, or
- Improper maintenance, etc.
Now for each of the above you can find underlying reasons, like for improper maintenance it could be there's no preventive maintenance or improper oiling or the wrong lubricants etc.
Now analyze out of all the reasons which is the most frequent reason and what among the sub-reasons you plotted is causing it.
This is the root cause for your breakdown. This whole exercise should not take more than 3 months to complete and you will surely discover a concrete problem to which you can then seek a solution.
Temporarily you could focus on:
- Protective and Preventive Maintenance
- Establishing shifts as 8-4-8-4 which is a Japanese technique where after every 8 hour shift, 4 hrs are being spent on cleaning, oiling, lubricating, and maintenance.