Troubleshooting 181

5 Why

A troubleshooting process that involves asking a series of “why” questions, usually five, in order to isolate the root cause of a problem. The 5 Why method can be incorporated into other troubleshooting techniques.

5M plus 1P

5M + 1P. A method commonly known as 6M that is used during brainstorming to help identify the six major factors most likely to be the source of problems. The 5M + 1P categories are machinery, materials, methods, measurements, Mother Nature (process), and people (manpower).

6M

A method sometimes known as 5M + 1P that is used during brainstorming to help identify the six major factors most likely to be the source of problems. The 6M categories are machinery, materials, manpower (people), methods, measurements, and Mother Nature (process).

80-20 rule

The belief that 80% of a problem is caused by 20% of variables. The 80-20 rule, also called the Pareto Principle, is often illustrated in Pareto charts.

brainstorm

An activity in which an individual or group rapidly lists ideas in order to identify possible problem causes or solutions. Brainstorming is most effective when conducted by a diverse employee pool that can provide different perspectives.

check sheet

A quality control form that uses marks to collect and record information about a problem by tracking categories and occurrences. Check sheets are typically simple forms that can be filled out on the shop floor, but they may also be produced by smart technology.

collaboration

The act of working with other people to achieve a desired end result. Collaboration during troubleshooting involves each individual sharing their ideas with the team, which can improve morale and cooperation among the team as a whole.

consensus

A result of collaboration in which everyone on a team has actively participated in crafting solutions. A consensus is reached when all team members can support the final decision.

consumables

Any material or substance that is used up in a process or wears out over time. Consumable materials do not contribute to the cost of a product.

continuous improvement

A lean manufacturing concept that describes an ongoing effort to make products, services, or processes better. Continuous improvement identifies opportunities for improvement, takes action to achieve improvement, analyzes the results, and implements workable solutions.

conveyor belt

A moving strip of material that carries parts or other components from one area of a manufacturing facility to another. Conveyor belts are commonly used to transport parts from production to packaging.

cumulative

The total sum of a range of values, which increases as each new value is added. The cumulative total of possible causes for a problem is shown in Pareto charts.

data

A collection of numbers, facts, and information about a process or product. Data can be created, communicated, and recorded by both employees and smart technology.

deviation

A situation that is less than ideal but is temporarily acceptable. Deviations can lead to parts that do not meet specifications.

documentation

The process of keeping records and information for reference and traceability purposes. Documentation provides a roadmap for future troubleshooters in case a problem reoccurs.

fishbone diagram

A visual chart that identifies and isolates potential causes of a problem. Fishbone diagrams list the problem in the center with the 6M categories branching off it, with possible causes branching out further from these.

hazard

Any source of potential damage, harm, or human health risk in the workplace. Hazards can be physical hazards, such as fires or falling objects, or health hazards, such as chemical exposures.

implementation

The act of taking a proposed solution and putting it into practice. Implementation requires monitoring to ensure the solution works in the long-term.

lean manufacturing

An approach to manufacturing that seeks to strengthen the efficiency of processes, increase flexibility, and improve quality. Lean manufacturing approaches help to eliminate waste in all its forms.

load

The amount of force or pressure placed on a component or system. Belt drives can sustain a range of light or heavy loads.

maintenance

The necessary and basic support and repair of machines that involves tasks such as lubricating, adjusting, and replacing machine parts. Maintenance helps to reduce machine breakdowns and ensure user safety.

Pareto chart

A visual tool used to distinguish the frequency of specific events occurring that lead to problems. Pareto charts often display the 80-20 rule.

problems

A situation that creates unacceptable quality or safety hazards. Problems must be corrected, usually as soon as possible.

pulley

A type of simple machine consisting of a circular device that raises or lowers a load or transmits motion. Pulleys drive the motion of a belt and can determine which direction the belt moves.

quality

Conformance to a set of standards or specifications that results in customer satisfaction in a product or service. Quality products are free of defects and meet the requirements of their anticipated use.

range

The difference between the smallest and the largest values within a numerical set. Range can show the variation in acceptable measurements.

raw materials

An unprocessed or lightly processed component used to make a finished part. Raw materials in manufacturing include metal, plastic, sand, and ceramic.

root cause

The true origin of a problem, as opposed to any resulting symptoms or effects. Troubleshooting attempts to determine the root cause in order to create a permanent solution.

sensors

A device that detects a change in a physical stimulus and turns it into a signal that can be measured or recorded. Sensors may be connected to a machine or system in order to collect operational data that is later analyzed.

slippage

A condition where a conveyor belt slides or does not move in the appropriate direction. Slippage occurs when the belt and pulley do not have a strong grip.

smart technology

A computing device that can send and receive data without human intervention. Smart technology generally requires internet connectivity to enable data processing.

solutions

A way of dealing with a problem so that the difficulty is removed. Solutions can be identified through troubleshooting a problem.

standardization

The process of establishing consistent and uniform ways of performing tasks or activities. Standardization eliminates the possibility of errors or problems arising from performing tasks or activities multiple ways.

symptoms

A sign that a process or operation did not work as expected. A symptom is a sign or aspect of a problem, but not the problem itself.

torque gage

A tool used to measure the amount of force used to produce rotation. Torque gages measure torque in Newton-meters (N-m).

traction

The ability of a moving object to remain in contact with the surface over which it moves. Traction keeps a belt in contact with a rotating pulley.

troubleshooters

A group of employees who cooperate to effectively solve a problem. Troubleshooters, also called troubleshooting teams, consist of workers from diverse areas of a company.

troubleshooting

A systematic, standardized approach to solving problems quickly and efficiently. Troubleshooting focuses on identifying the root cause of a problem and eliminating that cause to create a permanent solution.

troubleshooting teams

A group of employees who cooperate to effectively solve a problem. Troubleshooting teams, also called troubleshooters, consist of workers from diverse areas of a company.

variables

A changing or unknown value. Variables can affect the way a task is performed or impact the end results of a process.

windings

Wire wrapped around a core or into a coil that is used to conduct current. Windings create the magnetic field in a motor that makes the motor work.