P roblem S olving I nnovator Team problem solving in a production Environment

Seal Surface deteriorates Wrong Washer Damaged Washer Washer Hardness Porous Valve Casting Seal Distorted Inclusions in Valve Casting Casting too Hard (brittle) Damaged face of valve Parallelism Viscosity Smoothness Squareness Adaptor Smoothness Flatness Damaged face adaptor Equipment Breakdown Adaptor damaged thread Thread Pitch Foreign matter Damaged Thread Thread Length Bottom Viscosity of Fluid Adaptor damaged thread Thread Size Incorrect Set-up Interpretation of extent of Leakage Loss of Torque on Union Loss of Torque Missing Washer Over Torque in assembly Test Rig Setting Fitment damage - test Pressure Test Port Test Devt SOPS Different Operating Conditions Vibration of Valve Operational Use Higher Operating Pressure Poor Documentation Incompetent Tech/Engr RAW MATERIAL MACHINING TAPPING ASSEMBLY/TEST DESIGN/APPLICATION

Sealing Washer Valve Body Casting Thread Adaptor Casting Receiving Inspection

The FUNCTION describes each Process Step in a Process The Process Requirements generally reflect the Operating Conditions that are required for effective Process Control. The Product Requirement generally reflects the Specifications that must be achieved. The Failure Mode is defined as the manner in which the process could potentially fail to meet the Product or Process Requirements. The Failure Effect is defined as the consequences incurred in the event of an actual Failure. A Root Cause can be defined as a Product or Process or Design Weakness that may result in a failure. The Detection Controls are specific actions taken to detect the Failure Mode if it happens.

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