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GSI-Rec-020-09 Failure Analysis Form

This document appears to be a failure analysis template used to document a failure that occurred, investigate the root cause, and define corrective actions. Some key details: - It provides sections to document failure date/time, cost, classification, equipment involved, description of the failure, and participants in the analysis. - Annexures are referenced for tools to analyze root cause, including a fishbone diagram, 5 whys analysis, and fault tree analysis. - The action plan section lists proposed corrective actions, responsibilities, deadlines and documents to review. - Effectiveness of the analysis and actions will be verified against defined criteria, with revisions made if needed.

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Vi Kra
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146 views

GSI-Rec-020-09 Failure Analysis Form

This document appears to be a failure analysis template used to document a failure that occurred, investigate the root cause, and define corrective actions. Some key details: - It provides sections to document failure date/time, cost, classification, equipment involved, description of the failure, and participants in the analysis. - Annexures are referenced for tools to analyze root cause, including a fishbone diagram, 5 whys analysis, and fault tree analysis. - The action plan section lists proposed corrective actions, responsibilities, deadlines and documents to review. - Effectiveness of the analysis and actions will be verified against defined criteria, with revisions made if needed.

Uploaded by

Vi Kra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
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ASPL-Rec-020-09 Rev:05
FAILURE ANALYSIS
Date of the failure: FA Number: Type of Failure: Internal/ External

Date of Analysis: Cost of Failure: Repetitive: Yes/ No

Classification: Process System Product

Department & Section:


Equipment:
Component:
Trigger:

KPI Index:

Defect or Problem:
Batches / Materials
Batch Qty (kg) Material

Issuer:
Shift:
Start of the interruption: hh:mm:ss End of the interruption: hh:mm:ss

Total interruption time: minutes

Description of the failure:

Observation of the failure:

Correction/ Immediate Action:

Particpants
Annexure 01 - Fish Bone diagram
Annexure 02 - Why-Why Analysis Template
Annexure 03 - Fault Tree Analysis Template
Use one of the methods or combination of the methods,
for arriving at Root Cause.
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ANALYSIS OF THE PROBLEM (Annexure 01)

CAUSE AND EFFECT DIAGRAM

MACHINE MANPOWER
MEASUREMENT

Effect
-

METHOD MATERIAL ENVIRONMENT


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Annexure 02 - Why - Why Analysis


Note: Based on Failure, the tree can be expan

How Problem was created?

Why did this happen?

Why did this happen?

Why did this happen?

Why did this happen?


S.no
1
2
3
Generally Why - Why Analysis classified in to Three Categories
1
2
3
1.Why Problem occurred : Root cause is typically related to design, operations, dimensional issues, etc.
A
B
2.Why Problem was not detected ? : Root Cause typically related to the inspection system like ( Error proofing , No I
A
B
C
3.What is the systemic rootcause ? ( Root Cause typically related to management system issues or quality system fa
design,Lack of effective Preventive Maintenance system,Ineffective Advanced Product Quality Planning (FMEA, Con
A
B
C
Description
Ask “Why” until the root cause is uncovered (May be more than 5 Whys or less than 5 Whys)
If you are using words like “because” or “due to” during analysis, you will likely need to move to the next Why analysis
If you don’t ask enough “Whys”, you may end up with a “symptom” and not “root cause”.
Generally Why - Why Analysis classified in to Three Categories
Why Problem occurred
Why Problem was not detected ?
What is the systemic rootcause ?
1.Why Problem occurred : Root cause is typically related to design, operations, dimensional issues, etc.
Why did we have the specific non-conformance?
How was the non-conformance created?
2.Why Problem was not detected ? : Root Cause typically related to the inspection system like ( Error proofing , No Inspcetion , M
Why did the problem reach the customer?
Why did we not detect the problem?
How did the controls fail?
3.What is the systemic rootcause ? ( Root Cause typically related to management system issues or quality system failures Like (
design,Lack of effective Preventive Maintenance system,Ineffective Advanced Product Quality Planning (FMEA, Control Plans)))
Why did the problem reach the customer?
Why did we not detect the problem?
How did the controls fail?
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FAULT TREE ANALYSIS (Annexure 03)


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Action Plan
S.No. Action CA PA Accountable Deadline
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Documents to be reviewed
Review Required Document Who will When to
S.No. Document
(Yes or No) No. review review
1 Quality Manual
2 General Management Procedure
3 PFMEA
4 Control Plan
5 Routine procedure
6 Work Instruction
7 Job Aid
8 Record Format
Effectiveness verification
Evaluation criteria :
Deadline:
Accountable:
Observation:

Obs.: The last action of the action plan should always be how the verification of the effectiveness of the analysis

Effective analysis? Yes No

Participants

ACCOUNTABLE FOR THE ANALYSIS:


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Action Plan
Verification of the
How Close date
action

Prism upload
If revision required, what to be revised
(Done/ Not done)

ffectiveness verification

erification of the effectiveness of the analysis is going to be carried out

No Evaluation date:

MANAGER: DATE:

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