Coolant Contamination Fish Bone Diagram

1. C:Documents and SettingsbharriganDesktopSales MaterialsCase HistoriesCase Fishbone Toyoda 10-30-08.twd
Not a primary root cause
A losing battle to clean - Continants back in a day.
Should spray part at work station to remove chips
Reactive on housekeeping - collect or clean what is visible or unsafe:
Some machine tools overflow into pans, manually dumped into flume
Wrong product being added?
Observations: Filling: Operators fill way lube tanks (accessible) oil filler does the rest?
Compatibility
- lube alarm if spindle oil is low
Demulsibility
Changed over time? Spray inside of machine with coolant to "clean"
Way Demulsibility Observations
Impact:
Fixture Oil Next Steps:
Cost
Types on oil Hydraulic Ease____
Spindle
WCM Board
Coolant Synthetic vs Semi
Scheduling
Unknown practices
Impact: Unknown
Between Shift
Next Steps: Communications
Cost Communication
Observations
Ease____
Impact:
Hoses & fittings Next Steps:
Cost
Man
Worn seals on
Ease____
Wipers & gaskets way- due to wear and tear
rial
Fluid attacking seals Priorities
Machine Seals Seal issues Oil Overfill
Mate
Impact:4 Fairly High Harrigan available to train -
Next Steps: Cost: 2 Costly housekeeping relative to fluids
Ease: 2 Difficult Impact: 3
Workpiece metal
Training / Knowledge - Rolando 75 Cost: 5 Cheap Terry
Next Steps: Ease: 5 Easy____
Paint No Standard Tim
nell
More abrasive on Set time, topics, attendees Tom
machine components Lack of Cleaning Doug
Perso
Observations Observations
Chips Impact: Impact:
Michael
Next Steps: Next Steps: Jered
Cost Cost
Ease____ Ease____ Todd
Coolant Contamination
Slope Big issue
Lack of flushing Impact: 5 HIGH
Scheduling time to PM 6 Next Steps:
Lack of barriers Cost: 3
Floor Conditions Not a contributor Ease: 4 Easy
Impact: Centrifuges
Next Steps:
Cost Skimmers
Ease____
Settling tanks Size of tank
Plugged, Overflowing? Oil Removal Methods 4 Observations
Floats not working Impact: 5 High
Repair the units: Next Steps:
Settling tanks 36 Cost: 2 More costly
Impact: 4
Next Steps: Cost: 3
Ease: 4 Fairly Easy
Ease: 3 ( PVC Plumb back to system?)___ Frequency
Design - Inadequate sealing Poor seals Amount
(Designed for steel, have Cast Iron) Seals worn or missing Unsure of practices
Chip dams Impact: 5 High
ods
Way covers 8 Replace/Repair Seals or Covers: Cost: 5 Cheap
Ease: 4 Easy____
Next Steps:
Impact: 4 Highl
Way lube timers - Tom 100
Meth
Cost: 2 Costly 1 Check mfg specs
Ease: 1 Difficult Next Steps: (Tom)
Makinos 2 Verify current state
Cross contamination Retention knobs
Replace retention knobs 3 Monitor oilers
Spindle chillers 48 Impact: 3 Fairly High 4 Identify high usage machines
Next Steps: Cost: 4 Cheap One day
Ease: 4 Easy
#2 Coolant jet flush Flexible Machining Center
line in wrong spot Chip dams? Vehicle Delivery System
-not existing on Makinos Observations
2 Waylube troughs 100 Chip Dams definately a problem - Lack of appropriate Impact: 4 High
Operators need to address Collection method 8 Next Steps:
(Chip dams & build-up) - Rolando Next Steps: Impact: 4 High
Cost: 2 Costly
Ease: 1 Difficult____
Cost: 5 Cheap
Ease:_5 Easy Specifically Beneath Vehicle
Trough 100 Inadequate flushing Chip dams Comprehensive work order
Method of Repair
Bypass of solids Media Tracking Training?
Time, Pressure, at all? How disseminated
Paper slipping, ripped Priorities
Indexing Work Orders
Flights worn
Closure
Vacuum Filter 48 Clean chamber plugged
Replace filter
Impact: 4 High
Next Steps:
inery
Cost: 3 Medium
Ease: 4 Fairly Easy
WSPX 204
Mach
Henry System 330 Gal / wk
Undersized for current conditions
Centrifuge 75 - Todd Impact: 5 High
Next Steps: Cost: 3
Ease: 5 Easy
Propose centrifuge rental
Unknown - might be plugged
Needs to be checked, cleaned too?
SID Filter 36 Impact: 3 Medium (unknown)
Next Steps: Cost: 4 Fairly Inexpensive
Ease: 3 Fairly Difficult_ (shutdown)
Bag filters
(Collecting pan fluid discarded)
(Load & unload pans return to trough via hoses)
Next Steps: Impact: 1 Minimal
Cost: 3
Ease: 3 Medium____
Vehicle 9 No integral collection
Spaces between, under
Collection Pans
Pallet Stackers
Coolant dripping
Eye-sore
Potential Next steps: Kaizen Event
Is a source.
Impact: 4 High
Next Steps:
Toyodas Cost: ??
Ease: ??_____
Pallet Stackers
Many leaks!
Impact: 5 Very High
Next Steps: Cost: 4 Cheap
Ease: 3 Depends on access
Fittings, lines, Machine 258: Hopefully already addressed
No scheduled shutdown
sub-components 60
Notification?
Pressure switches...
Temp gauges missing
Slope of hoses
High Pressure Coolant System
Tooling
Load Station
Fixture Design 15
10/13/2010