Root cause Analysis

We tried to find out the fundamental cause of the issue at hand. With our
observation and analysis, we could enumerate the following probable causes:

Operator skill issues

Header cause: As this was a manual problem, the skill of the labourers come
into picture here and
that is where there is a scope of further efficiency
Problem: The basic problem in this area, as identofied by us was the missing
of pallets and thus, leading to the ultimate defect in the process.

Improper Acid Soaking

Header Cause: As this a procedural issue, the fundamental cause would be the
process being followed which can be further streamlined.
Problem: The problem identified in this case is an important function in the
entire operations, Sticking

Side shoe problem

Header Cause: As this a procedural issue, the fundamental cause would be the
process being followed which can be further streamlined.
Problem: The missing of pallet was analysed to be the basic problem in this
case.

Improper Grid Feeder width adjustment

Header Cause: As this is a technical issue, the basic cause is realted to the
equipment and the machinery being used in the process.
Problem: The fall down of the machinery being used was identified as the major
obstruction in the process.

Improper Grid Width setting

Header Cause: As this is a technical issue, the basic cause is realted to the
equipment and the machinery being used in the process.
Problem: The main issue in this case was bending which could be made
efficient by working on the technicalities of the machinery.

Coma roller issues

Header Cause: As this is a technical issue, the basic cause is realted to the
equipment and the machinery being used in the process.
Problem: The missing of pallet was analysed to be the basic problem in this
case which needs some attention for attaining efficiency.

Double grid sensor issue

Header Cause: As this is a technical issue, the basic cause is realted to the
equipment and the machinery being used in the process.
Problem: The rejection of hopper was identified to be the major issue at hand
which should be looked into for further efficiency.

Vacuum pump issue

Header Cause: As this is a technical issue, the basic cause is realted to the
equipment and the machinery being used in the process.
Problem: The problem in this case is similar to the problem in the previous
issue, Rejection of Hopper

Lug Passing guide

Header Cause: As this is a technical issue, the basic cause is realted to the
equipment and the machinery being used in the process.
Problem: Sticking was identified as the mojor glitch in the process.

Grid feeding setting

Header Cause: As this is a technical issue, the basic cause is realted to the
equipment and the machinery being used in the process.
Problem: Here, the fundamental problem again was the rejection of Hopper.

FD chain alignment issue

Header Cause: As this a procedural issue, the fundamental cause would be the
process being followed which can be further streamlined.
Problem: The problem of Deformation was the major glitch under this head.

The Fish Bone Diagram

High Rejection

We can classify the identified problems under the heading as is

illustrated in the finsh bone diagram

Man:

Operator skill issues

Machine:

Improper Grid Feeder width adjustment

Improper Grid Width setting
Coma roller issues
Double grid sensor issue
Vacuum pump issue

Lug Passing guide

Grid feeding setting

Method:

Improper Acid soaking

Side shoe problem
FD chain alignment issue

Material:

Grid Rejection Wire missing, bend, flash