Manpower No monitoring Discipline Not follow procedure Dirty hand Not wear gloves No gloves provided Discipline Not

serious Intend to produce parts as much as possible Pay by piece No guideline No standardize number of times of painting Try and error Trial Painting No training No procedure of tools setting Maintenance Machine down Complex setting parameter Wrong setting

Machine

Maintenance Blocked paint head Cooling time Improper bake temperature Blocked paint head Warehouse management Ink expired Supplier Color variation Inaccurate color verification by visual check Poor ink quality IQC Supplier Low efficiency in coloring department

Method

Material

Manpower No monitoring Not follow handling guideline Through the parts Lazy No monitoring Not follow polishing guideline Poor surface finishing Use Wrong Tools No guideline for machine setting Apply wrong setting to the machine Unclear guideline Material handling process No guideline Based on experience Machine Setting No guideline Based on experience Molding Process No standardized procedure Surface finishing process Method Mold design problem Mold broken Fatigue Complex setting parameter

Machine

Wrong setting for injection machine Maintenance Setting not precise Machine Down Maintenance Supplier Wrong material Improper hardness of parts Air bubble on surface of parts Impurities of material IQC Supplier Material Low efficiency in molding department

Product Handling
Why? Why?

Poor surface of parts

Why? Why?

Parts broken
Why?

Worker not wear gloves

Why?

Rubbing or crushing while transfer the part to next step

Why? Why?

Workers throw the parts

Why? Why?

No standardized guideline to follow

Why?

Place the parts randomly to tray

Why?

No regular audit
Why?

No monitoring
Why?

Work faster to produce more unit

Why?

No one set the guideline

Why?

Improper design of storage unit

Why?

Management do not request

Why?

No supervisor
Why?

Increase income
Why?

Department manager too busy

Why?

Management chose wrong design of storage unit and transportation method

No budget
Why?

No budget
Why?

Pay by piece
Why?

Insufficient manpower

Top management

Top management

Payroll policy

Surface Polishing
Why? Why?

Over / less polishing

Why? Why? Why?

Inappropriate fixture & equipment

Why? Why?

No skill of polishing
Why?

Work faster to produce more unit

Why?

Unclear instruction
Why?

Tools wearing
Why? Why?

Low quality of tool

Why?

Lack of training
Why?

Increase income
Why?

Lack of guideline
Why?

Huge amount of usage but lack of maintenance

Why?

Purchase problem
Why?

Supplier problem
Why?

No activity provided from molding department

Why?

Pay by piece
Why?

No guideline provide from molding department

Lack of manpower for maintenance

Why?

Budget issue
Why?

Relationship with supplier

Budget issue
Why?

Payroll policy

Recruitment
Why?

Top management

Top management

Top management

Coloring Process
Why? Why? Why?

Color Painted unevenly

Why?

Color not match

Why?

Paint out of boundary

Why?

Work faster to produce more unit

Why?

Color paint mix without specific formula

Why?

Spray before the parts in proper position

Why? Why?

Increase income
Why?

Correctness of color Is verified by eyesight

Why?

Spray gun can be operated no matter fixture is closed or not

Why?

Work faster to produce more unit

Why?

Pay by piece
Why?

No proper equipment to assist

No linkage of control between fixtures and spray gun

Why?

Increase income
Why?

Payroll policy

Limitation of existing equipment

Pay by piece
Why?

Payroll policy