ENGINEERING SYSTEM ANALYSIS

 
LINE / AREA : MACHINE / PROCESS: DATE: REF NO:

OWNER: FACILITATOR:
Notification no PARTICIPANTS 

PROBLEM IDENTIFIED (Clear Description / 1 Object and 1 Defect)

Be specific and factual, no assumptions. Problem statement should have 1 object and 1 defect.
Primary drive shaft (object) snapped (defect) or BBT 45 DO (object) 40 ppb above spec
(defect)
A MAINTENANCE SYSTEM YES NO Comments / observations
1 Is there an inspection task for this failure?    
2 Is there description adequate to pick up wear/      
In an Engineering
damaged before failure?
System analysis all
3 theIspossible
the frequency of inspection adequate?      
4 systemic
Is the inspection
gaps are standard clear      
5 identified that shooting guide (WI5) available
Is the trouble
could have
6 Is the failureled to
covered in WI 5
the situational
7 Is this failure a frequent problem?      
failure or defect
8 Are special tools required to perform this task?      
9 Are the special tools available to perform the task?
B MAN ( Talk to people involved to obtain their YES NO Comments / observations
views)
1 Name of work centre that performed the last    
Answer all the
inspection and when?  
questions with
2 factual
Is the work centre deemed competent on the above      
schedule?
information.
3 Is the area of failure the work centre’s area of      
responsibility?
4 If any
Wasofthere
the sufficient time to complete the schedule      
C responses
MATERIAL to a YES NO Comments / observations
1 Is the failedincomponent
question fall a composition as per original      
grey blockand
design it points
quality?
to a potential
2 Is the correct spare for failed equipment kept in the      
systemic cause
stores and readily available?
D MACHINE YES NO Comments / observations
1 Was a modification on the equipment/process/ plc      
made recently?
3 Is this failure/ problem a result of secondary      
damage due to modification/ work performed
elsewhere?
1 Based on findings from the above what is the root cause(s) of
Root Cause Description:- this problem
2
Where has the system failed to allow this root cause to happen?
What has caused this cause Root cause can be competence of person who executed the task
(Systemic Gap) but the systemic cause might be staff shortage or not adhering
to on-boarding and CAP rules. 
 
 LOOP CLOSURE
PREVENTATIVE ACTION PLAN DUE WO/ COMMENTS
SCHED NO
   
 Capture all the agreed actions to prevent this  
problem from recurring. Actions must focus on
Progress
When with
actions
eliminating root loop through design-out or
are
cause
poke yoke designs.need
closure
captured actions
as works Also to
address the systemic
be
ordermonitored
record the regularly
gaps - refer to loop closure list below to identify
and feedback
number
actions here captured

MAINTENANCE PROGRAM OPERATIONS

MSG3   Start up  
New/change schedule (PM / ATM / SA)   External Cleaning / inspection  
Problem solving guide (QFR & WI 5)   Changeovers (brand / BBT / Pack)  
End state   Corrective actions (QFR)  
Work instruction (1-9)   Waste  
Training   Shutdown  
  Downtime  
STORES   CIP  
Bin level   Workstation Job aids  
Reorder level This section serves as Training
QC part inspection a memory jogger to   Quality and Waste  
assist the team in
New stock item identifying all the
  Safety Health and Environment  
Retrieval time required loop closure  Running  
actions – tick off the  Autonomous Maintenance  
required items and
QUALITY add appropriate
Quality input action to action plan  EQUIPMENT
above
Quality output   Modifications  
Job aids    
Training   INFORMATION
Work instructions   Machine drawings  
QC Equipment Maintenance   Procedures  
  Suppliers manuals  
OTHER ACTIONS      
 

THINK BEYOND THE FIX

Where else are similar equipment/processes where the same problem/defect can also Actioned
occur (list)
To prevent the same failure or defect in other similar equipment or processes it is important to identify where
else the same incident is likely to happen. Take preventive action within your own line/area and ensure this is
communicated to the other teams. 
 
Are there any opportunities from the list of remaining possible failure causes?  
During the above investigation of possible causes team members might see other potential problems or conditions
that need attention. List those items here and ensure actions are recorded in team gaplist

SIGN OFF
Investigation fully completed, all actions done Yes No ( If No – Open Stage 1)