FishBone - 5 Why - V6

• Document No.

• Conducted on

  Date

• Prepared by

• Data Base Assigned NCF Number: (Include "NCF" prefix)

• Job Number / Lot Number:

• Part number / Operation Number / NCF Feature Inspection No. / NCF Feature

• Location / Machine number
  Address

• Personnel: Investigation Supporting Associates

• Take Picture of Part.

  Media

Description of Non-conformance and Investigation Notes:

• Description of Non-conformance (include the dimension, tolerance, B/P note and/or specification requirement):

• Enter B/P or Operation Requirement:

• Enter Actual NonConforming Results:

• Investigation Notes:

• Add media

  Media

Method

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Work Instructions incomplete, inadequate and not precise.<br>(Set up Sheet, Tool Sheet, Program Instructions, Quality Plan)

  0

  1

  2

  3

  5

• Program Mathematically incorrect.<br>

  0

  1

  2

  3

  5

• Feeds & Speeds not viable for the designated tooling.

  0

  1

  2

  3

  5

• Part fixture & part location surfaces not cleaned prior to loading the part.<br>

  0

  1

  2

  3

  5

• Program/process changed during or from last time job was run.

  0

  1

  2

  3

  5

• Operation performed out of sequence.

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Measurement

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Inspection methods inadequate & unacceptable.<br>

  0

  1

  2

  3

  5

• Gauging inadequate for the dimensions called out?<br>(Type, Resolution, Repeats, Can accurately measure the dimension)

  0

  1

  2

  3

  5

• Gages out of Calibration date.<br>

  0

  1

  2

  3

  5

• Gage allows incorrect readings<br>

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Machine

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• TPM inadequate and not up to date.<br>

  0

  1

  2

  3

  5

• Coolant and coolant levels inadequate and does not meet the requirements.<br>

  0

  1

  2

  3

  5

• Coolant added to machine during process.<br>

  0

  1

  2

  3

  5

• Machine not capable to produce the operation requirements.<br>

  0

  1

  2

  3

  5

• Machine malfunction.<br>

  0

  1

  2

  3

  5

• Probing error.<br>

  0

  1

  2

  3

  5

• Tooling/Tool holders inadequate to produce the dimensions.<br>

  0

  1

  2

  3

  5

• Tooling/Tool Holder worn.<br>

  0

  1

  2

  3

  5

• Manually adjusted tool adjusted (IE: boring bar adjustment).

  0

  1

  2

  3

  5

• Fixture inadequate and unload friendly.<br>

  0

  1

  2

  3

  5

• Fixture locations, clamps worn.<br>

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Mother Nature

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Power failure.<br>

  0

  1

  2

  3

  5

• Power surge.<br>

  0

  1

  2

  3

  5

• Lighting inadequate.

  0

  1

  2

  3

  5

• Shop temperature not within the acceptable limits.<br>

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Material

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Incorrect Material being used.<br>

  0

  1

  2

  3

  5

• Material hardness not within the required limits.

  0

  1

  2

  3

  5

• Casting or forging not within the Blueprint requirements.<br>

  0

  1

  2

  3

  5

• Dimensional size of raw material (non forged or cast material) or from prior operation not within required dimensional limits. <br>

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Man

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Associate does not understand all the work instructions.

  0

  1

  2

  3

  5

• Associate did not follow all of the work instructions.<br>

  0

  1

  2

  3

  5

• Associate does not have enough experience/training to perform task.<br>

  0

  1

  2

  3

  5

• Associate performing more than one task (IE: double machine).<br>

  0

  1

  2

  3

  5

• Clamping method not maintained.<br>

  0

  1

  2

  3

  5

• Loading method not maintained.<br>

  0

  1

  2

  3

  5

• Offset change made.<br>

  0

  1

  2

  3

  5

• Manually adjusted tool adjusted incorrectly (IE: boring bar adjustment).

  0

  1

  2

  3

  5

• Double check of offsets at time of set-up and tool change not performed.

  0

  1

  2

  3

  5

• Gage being read incorrectly.<br>

  0

  1

  2

  3

  5

• Dimensional inspection frequency not maintained. <br>

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

5 Why - Primary

• What is the primary cause?

• Why 1 - Why did this occur?

• Why 2 - Why did why 1 occur?

• Why 3 - Why did why 2 occur?

• Why 4- Why did why 3 occur?

• Why 5 - Why did why 4 occur?

• Root Cause:

• Add media

  Media

• Why Code:

  Select WY 101 - Fixture – Cannot hold location tolerance WY 102 - Fixture – Repeatability WY 103 - Fixture - Worn WY 104 - Fixture - Clamping WY 105 - Fixture - Calibration WY 106 - Fixture – Allows incorrect loading of part WY 107 - Fixture – Load/Unload interference WY 108 - Fixture – Not loaded onto machine correctly WY 109 - Machine Tool – Repeatability/Accuracy WY 110 - Machine Tool - Maintenance WY 111 - Machine Tool – Malfunction WY 112 - Handling/Transport - Inadequate WY 113 - Handling/Transport – Lack of protection devices WY 114 - Tooling – Insufficient/ Incorrect WY 115 - Tooling - New, Prove out WY 201 - Process Sheet – Missing dimension WY 202 - Process Sheet – Inadequately toleranced WY 203 - Process Sheet – Allows for misinterpretation WY 204 - Work Instruction/Procedure – does not exist WY 205 - Work Instruction/Procedure - Insufficient WY 206 - Work Instruction/Procedure – Allows for misinterpretation WY 207 - Process – Not capable WY 208 - Process – New. Did not react as planned WY 209 - Process – Step missed/performed out of sequence WY 210 - Customer supplied Tech Data incorrect/incomplete WY 211 - Inspection – Incorrect method used WY 212 - Inspection – Missing from Inspection checklist WY 213 - Inspection – Missing from CMM Program WY 214 - Program – Feed/Speed adjustment WY 215 - Program incorrect WY 216 - Method – No check and balance WY 301 - Material – Incorrect Material WY 302 - Material - Hardness WY 303 - Material – Not to B/P Requirements WY 304 - Packaging – Materials used WY 305 - Packaging – Lack of Instructions WY 306 - Tooling – Incorrect Grade/Type WY 307 - Tooling – Inadequate for Task WY 401 - Temperature WY 402 - Power Failure WY 403 - Power Surge WY 501 - Gauge – Incorrect resolution for tolerance WY 502 - Gauge – Not calibrated WY 503 - Gauge – Worn out WY 504 - Gauge - Broken WY 505 - Gauge – Incorrect Gauge WY 506 - Gauge – Not set correctly WY 507 - Gauge - Insufficient/Inadequate WY 508 - Gauge - Misread WY 601 - Training – Lack of / Insufficient WY 602 - Communication – Lack of / Insufficient WY 603 - Data Entry - Offset WY 604 - Process not followed/misinterpreted WY 605 - Customer Tech Data misinterpreted WY 606 - Data Entry - Vista WY 607 - Data Entry – Wrong program loaded WY 608 - Data Entry – Incorrect program edit WY 701 - Isolated WY 702 - Undeterminable WY 703 - Supplier Issue NCF Not Valid

  • WY 101 - Fixture – Cannot hold location tolerance
  • WY 102 - Fixture – Repeatability
  • WY 103 - Fixture - Worn
  • WY 104 - Fixture - Clamping
  • WY 105 - Fixture - Calibration
  • WY 106 - Fixture – Allows incorrect loading of part
  • WY 107 - Fixture – Load/Unload interference
  • WY 108 - Fixture – Not loaded onto machine correctly
  • WY 109 - Machine Tool – Repeatability/Accuracy
  • WY 110 - Machine Tool - Maintenance
  • WY 111 - Machine Tool – Malfunction
  • WY 112 - Handling/Transport - Inadequate
  • WY 113 - Handling/Transport – Lack of protection devices
  • WY 114 - Tooling – Insufficient/ Incorrect
  • WY 115 - Tooling - New, Prove out
  • WY 201 - Process Sheet – Missing dimension
  • WY 202 - Process Sheet – Inadequately toleranced
  • WY 203 - Process Sheet – Allows for misinterpretation
  • WY 204 - Work Instruction/Procedure – does not exist
  • WY 205 - Work Instruction/Procedure - Insufficient
  • WY 206 - Work Instruction/Procedure – Allows for misinterpretation
  • WY 207 - Process – Not capable
  • WY 208 - Process – New. Did not react as planned
  • WY 209 - Process – Step missed/performed out of sequence
  • WY 210 - Customer supplied Tech Data incorrect/incomplete
  • WY 211 - Inspection – Incorrect method used
  • WY 212 - Inspection – Missing from Inspection checklist
  • WY 213 - Inspection – Missing from CMM Program
  • WY 214 - Program – Feed/Speed adjustment
  • WY 215 - Program incorrect
  • WY 216 - Method – No check and balance
  • WY 301 - Material – Incorrect Material
  • WY 302 - Material - Hardness
  • WY 303 - Material – Not to B/P Requirements
  • WY 304 - Packaging – Materials used
  • WY 305 - Packaging – Lack of Instructions
  • WY 306 - Tooling – Incorrect Grade/Type
  • WY 307 - Tooling – Inadequate for Task
  • WY 401 - Temperature
  • WY 402 - Power Failure
  • WY 403 - Power Surge
  • WY 501 - Gauge – Incorrect resolution for tolerance
  • WY 502 - Gauge – Not calibrated
  • WY 503 - Gauge – Worn out
  • WY 504 - Gauge - Broken
  • WY 505 - Gauge – Incorrect Gauge
  • WY 506 - Gauge – Not set correctly
  • WY 507 - Gauge - Insufficient/Inadequate
  • WY 508 - Gauge - Misread
  • WY 601 - Training – Lack of / Insufficient
  • WY 602 - Communication – Lack of / Insufficient
  • WY 603 - Data Entry - Offset
  • WY 604 - Process not followed/misinterpreted
  • WY 605 - Customer Tech Data misinterpreted
  • WY 606 - Data Entry - Vista
  • WY 607 - Data Entry – Wrong program loaded
  • WY 608 - Data Entry – Incorrect program edit
  • WY 701 - Isolated
  • WY 702 - Undeterminable
  • WY 703 - Supplier Issue
  • NCF Not Valid

• Corrective Action:

• Add media

  Media

• Complete if primary cause RCCA level is insufficient or needs further action to help reduce chance of Nonconformance reoccurring.

• Perform Secondary 5 Why?

Secondary 5 Why

5 Why Secondary

• What is the Secondary cause?

• Why 1 - Why did this occur?

• Why 2 - Why did why 1 occur?

• Why 3 - Why did why 2 occur?

• Why 4 - Why did why 3 occur?

• Why 5 - Why did why 4 occur?

• Root Cause:

• Add media

  Media

• Why Code:

  Select WY 101 - Fixture – Cannot hold location tolerance WY 102 - Fixture – Repeatability WY 103 - Fixture - Worn WY 104 - Fixture - Clamping WY 105 - Fixture - Calibration WY 106 - Fixture – Allows incorrect loading of part WY 107 - Fixture – Load/Unload interference WY 108 - Fixture – Not loaded onto machine correctly WY 109 - Machine Tool – Repeatability/Accuracy WY 110 - Machine Tool - Maintenance WY 111 - Machine Tool – Malfunction WY 112 - Handling/Transport - Inadequate WY 113 - Handling/Transport – Lack of protection devices WY 114 - Tooling – Insufficient/ Incorrect WY 115 - Tooling - New, Prove out WY 201 - Process Sheet – Missing dimension WY 202 - Process Sheet – Inadequately toleranced WY 203 - Process Sheet – Allows for misinterpretation WY 204 - Work Instruction/Procedure – does not exist WY 205 - Work Instruction/Procedure - Insufficient WY 206 - Work Instruction/Procedure – Allows for misinterpretation WY 207 - Process – Not capable WY 208 - Process – New. Did not react as planned WY 209 - Process – Step missed/performed out of sequence WY 210 - Customer supplied Tech Data incorrect/incomplete WY 211 - Inspection – Incorrect method used WY 212 - Inspection – Missing from Inspection checklist WY 213 - Inspection – Missing from CMM Program WY 214 - Program – Feed/Speed adjustment WY 215 - Program incorrect WY 216 - Method – No check and balance WY 301 - Material – Incorrect Material WY 302 - Material - Hardness WY 303 - Material – Not to B/P Requirements WY 304 - Packaging – Materials used WY 305 - Packaging – Lack of Instructions WY 306 - Tooling – Incorrect Grade/Type WY 307 - Tooling – Inadequate for Task WY 401 - Temperature WY 402 - Power Failure WY 403 - Power Surge WY 501 - Gauge – Incorrect resolution for tolerance WY 502 - Gauge – Not calibrated WY 503 - Gauge – Worn out WY 504 - Gauge - Broken WY 505 - Gauge – Incorrect Gauge WY 506 - Gauge – Not set correctly WY 507 - Gauge - Insufficient/Inadequate WY 508 - Gauge - Misread WY 601 - Training – Lack of / Insufficient WY 602 - Communication – Lack of / Insufficient WY 603 - Data Entry - Offset WY 604 - Process not followed/misinterpreted WY 605 - Customer Tech Data misinterpreted WY 606 - Data Entry - Vista WY 607 - Data Entry – Wrong program loaded WY 608 - Data Entry – Incorrect program edit WY 701 - Isolated WY 702 - Undeterminable WY 703 - Supplier Issue NCF Not Valid

  • WY 101 - Fixture – Cannot hold location tolerance
  • WY 102 - Fixture – Repeatability
  • WY 103 - Fixture - Worn
  • WY 104 - Fixture - Clamping
  • WY 105 - Fixture - Calibration
  • WY 106 - Fixture – Allows incorrect loading of part
  • WY 107 - Fixture – Load/Unload interference
  • WY 108 - Fixture – Not loaded onto machine correctly
  • WY 109 - Machine Tool – Repeatability/Accuracy
  • WY 110 - Machine Tool - Maintenance
  • WY 111 - Machine Tool – Malfunction
  • WY 112 - Handling/Transport - Inadequate
  • WY 113 - Handling/Transport – Lack of protection devices
  • WY 114 - Tooling – Insufficient/ Incorrect
  • WY 115 - Tooling - New, Prove out
  • WY 201 - Process Sheet – Missing dimension
  • WY 202 - Process Sheet – Inadequately toleranced
  • WY 203 - Process Sheet – Allows for misinterpretation
  • WY 204 - Work Instruction/Procedure – does not exist
  • WY 205 - Work Instruction/Procedure - Insufficient
  • WY 206 - Work Instruction/Procedure – Allows for misinterpretation
  • WY 207 - Process – Not capable
  • WY 208 - Process – New. Did not react as planned
  • WY 209 - Process – Step missed/performed out of sequence
  • WY 210 - Customer supplied Tech Data incorrect/incomplete
  • WY 211 - Inspection – Incorrect method used
  • WY 212 - Inspection – Missing from Inspection checklist
  • WY 213 - Inspection – Missing from CMM Program
  • WY 214 - Program – Feed/Speed adjustment
  • WY 215 - Program incorrect
  • WY 216 - Method – No check and balance
  • WY 301 - Material – Incorrect Material
  • WY 302 - Material - Hardness
  • WY 303 - Material – Not to B/P Requirements
  • WY 304 - Packaging – Materials used
  • WY 305 - Packaging – Lack of Instructions
  • WY 306 - Tooling – Incorrect Grade/Type
  • WY 307 - Tooling – Inadequate for Task
  • WY 401 - Temperature
  • WY 402 - Power Failure
  • WY 403 - Power Surge
  • WY 501 - Gauge – Incorrect resolution for tolerance
  • WY 502 - Gauge – Not calibrated
  • WY 503 - Gauge – Worn out
  • WY 504 - Gauge - Broken
  • WY 505 - Gauge – Incorrect Gauge
  • WY 506 - Gauge – Not set correctly
  • WY 507 - Gauge - Insufficient/Inadequate
  • WY 508 - Gauge - Misread
  • WY 601 - Training – Lack of / Insufficient
  • WY 602 - Communication – Lack of / Insufficient
  • WY 603 - Data Entry - Offset
  • WY 604 - Process not followed/misinterpreted
  • WY 605 - Customer Tech Data misinterpreted
  • WY 606 - Data Entry - Vista
  • WY 607 - Data Entry – Wrong program loaded
  • WY 608 - Data Entry – Incorrect program edit
  • WY 701 - Isolated
  • WY 702 - Undeterminable
  • WY 703 - Supplier Issue
  • NCF Not Valid

• Corrective Action:

• Add media

  Media