What can be Root Cause Analysis Methodology - Heat Treatment of Carbon-based Products

W

wny4ever

#1
We employ a multiple process system of forming, heat treating, densifying, heat treating, final heat treat (extremely high temperature), and machining for the manufacture of our carbon-based product. In our largest cross-section product, we are experiencing product failure (internal structure). For the slightly smaller cross-section products, with the same process system, there is generally no such problem. The manufacturing process takes about 2 months, with hundreds of process variables, including inherently variable raw materials. The customer application is basically the same among customers, but the severity of their process conditions vary widely.
Using 5 Whys, 8D, fishbone, etc., seems just too simplistic for this complex manufacturing system. We are using DOE to explore continual improvement of our products/processes. We recently have also employed the Shainin Red X process, with seemingly good results at first, but now the results are uncertain.
My question is what advice can be offered as far as what type of methodolgy to use for root cause analysis?
 
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Stijloor

Staff member
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#2
Re: What can be Root Cause Analysis Methodology - Heat Treatment of Carbon-based Prod

We employ a multiple process system of forming, heat treating, densifying, heat treating, final heat treat (extremely high temperature), and machining for the manufacture of our carbon-based product. In our largest cross-section product, we are experiencing product failure (internal structure). For the slightly smaller cross-section products, with the same process system, there is generally no such problem. The manufacturing process takes about 2 months, with hundreds of process variables, including inherently variable raw materials. The customer application is basically the same among customers, but the severity of their process conditions vary widely.
Using 5 Whys, 8D, fishbone, etc., seems just too simplistic for this complex manufacturing system. We are using DOE to explore continual improvement of our products/processes. We recently have also employed the Shainin Red X process, with seemingly good results at first, but now the results are uncertain.
My question is what advice can be offered as far as what type of methodolgy to use for root cause analysis?
My experience with root cause analysis is that folks are trying to bite off too much. Often, the problem experienced is poorly defined; opinions, rather than facts and the scope is poorly defined as well. A possible suggestion is to break the problem up based the various processes that may have contributed to the issue. A process flow diagram can help to "chop up" the problem into manageable pieces.

Stijloor.
 
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D

Duke Okes

#3
Re: What can be Root Cause Analysis Methodology - Heat Treatment of Carbon-based Prod

For chemical processes basic RCA (5-whys, etc.) is unlikely to be powerful enough, and Shainin technique are much better suited to discrete manufacturing. DOE is likely to be your best bet, assuming you have a lot of variables, several of which could be interacting.
 
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B

bhmdave

#4
Re: What can be Root Cause Analysis Methodology - Heat Treatment of Carbon-based Prod

I would agree that DOE is likely to be the best way to go, and breaking the process into smaller steps can be helpful. I have found that defining the problem is crucial and then using a fishbone diagram to generate potential variables for the DOE works well.
 
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wny4ever

#5
Re: What can be Root Cause Analysis Methodology - Heat Treatment of Carbon-based Prod

We have broken down the root cause analysis into our manufacturing processes, with the first Shainin methodology application resulting in the Red X being a process variable in the forming process (that we consider to be important but not critical). Our scenario is made "tough", by the number of batch processes in the chain, the magnitude of the number of variables, the long processing time, and the variable raw materials.
 
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somashekar

Staff member
Admin
#6
Re: What can be Root Cause Analysis Methodology - Heat Treatment of Carbon-based Prod

We have broken down the root cause analysis into our manufacturing processes, with the first Shainin methodology application resulting in the Red X being a process variable in the forming process (that we consider to be important but not critical). Our scenario is made "tough", by the number of batch processes in the chain, the magnitude of the number of variables, the long processing time, and the variable raw materials.
Hi, It would also help if you can describe your input raw material and final products a bit more, and perhaps its typical applications ...
 
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