3W1H ANALYSIS FOR INTERNAL CORRECTIVE ACTIONS Date:

Stage: PDC FURNACE / TOP HEATING

S.NO COMPONENT NAME WHAT WHY WHO HOW RESPONSIBILITY NAME

& SIGNATURE

PLAN EVERY 6 DAYS ONCE

180/250 C /350 TON TOP COIL BROKEN / PIPE BROKEN / SLUG CLEANING WITH
1 DUE TO SLUG FORMATION PDC / MAINTENACE
HEATING LEG BROKEN PROPER PROCEDURE
WITHOUT FAIL.

CLEAN THE METAL

PROPERLY BEFORE
POURING TO TOP HEATING

MAINTAIN METAL TEMP

2 HOLDING FURNACE COIL BROKEN METAL TEMP RAISED PDC / MAINTANANCE BELOW 680 / TIMER AND
ABOVE 720 CUT OFF LEVEL FOLLOW UP
 3W1H ANALYSIS FOR INTERNAL CORRECTIVE ACTIONS Date:

Stage: PDC Target Efficiency: 85 % NO MANPOWER

S.NO COMPONENT NAME WHAT WHY WHO HOW RESPONSIBILITY NAME

& SIGNATURE

MANPOWER ISSUE - ABSENTISM PLAN TO GIVE ONE DAY

1 NO MAN POWER CONTIONOUS WORKING HR / PDC LEAVE IN A WEEK MUST
WITHOUT INFORMATION PER EMPLOYEE

INSTRUCT TO OPERATOR
FOOD HABITS AND AVOID
HEALTH ISSUE HR / PDC UNHEALTHY FOODS /
DIECASTING REALATED
PRECAUTIONS

PLAN TO PROHIBT
UNWANTED SHIFT
SHIFT CHNAGE HR / PDC CHANGES FREQUENTLY /
FIX STANDARD SHIFT
SCHEDULE

ACCOMDATION FACILITIES
ROOM FACILITIES - NOT HR / PDC NOT GOOD /MAKE THAT
SUFFICIENT
GOOD WITH HR SERVICE

SETTING ISSUE -QUALITY INSTRUCT TO OPERATOR /

ISSUE NOT CORRECTING PROVIDE TRAINING /
2 LOW EFFICIENCY HOURLY OUTPUT NOT GAINED AS UNSKILLED OPERATOR PDC STANDARDIZR THE
PER TARGET NO TRAINING CHNAGE SETTING /SORT OUT
OPERATOR MACHINE TO DISTURBANCES WHILE
MACHINE DAILY PRODUCTION
 3W1H ANALYSIS FOR INTERNAL CORRECTIVE ACTIONS Date:

Stage: PDC Target Efficiency: 85 %

S.NO DESCRIPTION SHOTS MAJOR DOWN TIME RESPONSIBILITY NAME

& SIGNATURE

PRODUCTION PLAN 100 605236 MACHINE BREAK DOWN 257.8

TON TO 730 TON

PRODUCTION ACTUAL
( 100 TON TO 315763 DIE BREAK DOWN 141.5
730 TON )

METAL CHARGE / FURNACE

EFFICIENCY 52%
BREAK DOWN

NO MANPOWER /
PRODUCTION GAP 289473 ABSENTISM / LOW 236.15
EFFICIENCY

DIE SETTING 830.3

 3W1H ANALYSIS FOR INTERNAL CORRECTIVE ACTIONS Date:

Stage: PDC MACHINE BREAK DOWN

S.NO DESCRIPTION WHAT WHY WHO HOW RESPONSIBILITY NAME

& SIGNATURE

INJECTION SENSOR ISSUE /

1
INJECTION DTP SENSOR MACHINE OFF WHEN PRESSURE DTP FAILURE SERVICE PERSON NEED TO CHANGE NEW
ISSUE -125
NOT DEVELOP

INJECTION IP NOT INJECTION IP PRESSURE NOT MONTHLY ONCE NED TO

2 N2 GAS ISSUE SERVICE PERSON
DEVELOP -250 B DEVELOP VERIFY N2 GAS LEVEL

3 EXTRACTOR ISSUE -420 A EXTRACTOR ISSUE CHUCK WEARED MAINTEANACE / PDC NEED TO CHANGE NEW

250 A LADDLE ISSUE /730

4 LADDLE COUPLING ISSUE COUPLING BROKENED MAINTEANACE / PDC NEED TO CHANGE NEW
TON LADDLE ISSUE

5
420 A *B CORE SENSOR CORE SENSOR FAILURE WIRING WRONG MAINTEANACE / PDC STANDARD
FAILURE CONNECTION
 3W1H ANALYSIS FOR INTERNAL CORRECTIVE ACTIONS Date:

Stage: PDC DIE BREAK DOWN

S.NO COMPONENT NAME WHAT WHY WHO HOW RESPONSIBILITY NAME

& SIGNATURE

EVERY 2000 SHOTS ONCE

1 BPU / FAN HOUSING CORE PIN BROKEN CORE PIN LIFE NOT GOOD DIE SERVICE CORE PIN NEED TO
CHANGE .

DIE COAT APPLY NOT NEED TO TRAIN UNSKILLED

SUFFICIENT / NOT OPERATOR .WHICH AREA
2 CATCH UP ISSUE OPERATOR / SUPERVISOR
PROPER SETTING AUTO IMPORTANT IN DIE MUS
SPRAY FOCUS

DUE TO HIGH TEMP PIN

WILL BROKENED / NOT EVERY 8 HRS ONCE FOCUSS
3 EJECTION PIN BROKEN EJECTION PIN BROKEN DIE SERVICE / PDC PIN CONDITION / COOL THE
PROPER COOLING PIN
AVAILABLE
CASTING CATCH
UP

6
 3W1H ANALYSIS FOR INTERNAL CORRECTIVE ACTIONS Date:

Stage: PDC Target : 30 MINS DIE SETTING

S.NO COMPONENT NAME WHAT WHY WHO HOW RESPONSIBILITY NAME

& SIGNATURE

WHILE LOADING NOT PROPER CLEANING / AVOID

1 COOLING NIPPLE COOLING NIPPLE DAMAGE CLEANING / WRONG DIE SETTER
THREAD WRONG LOADIG.

WATER HOSES DAMAGED / NOT FOCUSING USAGE TIE HE HOSES WITH

2 WATER HOSES DAMAGE METHOD / NOT CLEANING DIE SETER PROPER PROCEDURE /
BLOCKED HOSES ONCE IN A MONTH AVOID WRONG THREAD /

PLAN TO PURCASE
3 CORE SENSOR DAMAGE CORE SENSOR DAMAGE SENSOR HANDLING TOO DIE SETTER MACHINE VICE
WORST / NOT STANDARD ARRANGEMENTS / AVOID
WRONG PLUGGIN