El proposito de este archivo es organizar la informacion relevante

Documento # CORP-2233
Fecha efectiva 11/29/2017
Revision 2
Document Owner Harmon, Timothy P.

La siguiente hoja esta contenida en el libro de

trabajo:
Area Hoja de trabajo(links) Descripcion
Titulo Damaged screws on steelastic extruder head
Version Evolution of this workbook and contributors
Investigacion Contactos People / Contact info of those involved with the analysis
Flujo de trabajo RCA LV2 Workflow process
CM Pasos Cause Mapping Method, Steps and Tools (layout)
Comience Aqui Paso 1. Define el problema 1. Problema Damaged screws on steelastic extruder head

Paso 2. Conduce analisis 2. Herramienta de analisis 5-Why basic Cause Map to get started

Paso 3. Seleccione las soluciones 3. Soluciones

Paso 4. Complete la carta 4. Charter CTLSS Charter

Linea de tiempo Sequence of events with date, time, description
Diagrama Diagrams, drawings and images
Informacion adicional y herramientas Fotos Photographs and pictures
Mapa de proceso Steps of related work processes written as a flowchart
Notas Notes, emails, documents
Informacion Information to collect or To Dos during the investigation
Recursos Fin Extra material past this worksheet
Sugerencias Tips for using the template in Microsoft® Excel®
 Junta de informacion y participantes

Localizacion: AREA DE PREPARADO

Junta de info Fecha/Tiempo: 23-May-18
Duracion: 30 minutos

Nombre Localizacion Puesto Email Oficina Mobile

RUBEN DIAZ RELIABILITY RELIABILITY ENGINEER A2 [email protected] SALA DE ASSET CARE 3335596528
ALEJANDRO ESPARZA MTTO AREA 2 ING ELECTRONICO
ALFREDO ZAVALA AREA DE STEELASTIC MAESTRO OBRERO STEEL AREA DE PREPARADO
Participantes
ADAN GONZALEZ ATS RELIABILITY ENGINNER ATS ALMACEN DE REFACCIONES

Notas:

LA FALLA DEL MODULO DE PRESION DE LA MAQUINA STEELASTIC NO.3 DISPARO ESTE ANALISIS DE SEGUNDO NIVEL LOS DIAS 2,3,4 DE MAYO DEL 2018 POR EL TIEMPO DE LA CORRECCION
DE FALLA EN EL LAZO DE CONTROL.
 RCA LEVEL 2 WORKFLOW

Bad Actors Level 2

from Assigned by Bad Actors
Operations by Reliability (Data Mining)
Manager

Close Charter
5-why Team/ 5-why not Send to R.E. for Elevate to Team Create Charter Action Item Create Action
MRT lead resolved review Level 2 RCA meeting/Fault and send to BB Meeting Items in ETQ
completes RCA Tree Provide Complete
updates in MRT action items/
meeting Close RCA

Return to 5-
why team if
additional work
needed
 Problem Solving • Incident Investigation • Root Cause Analysis • Risk Mitigation Additional Tools - Use as needed to capture specific information during the investigation.

1 Timeline Diagram Photos Work Process Notes

Problem
Step 1 Define the Problem in the Problem Outline Timeline
Date Time Description
Diagram
Use the drawing tools to add any diagram to this work sheet. Example objects
Photos Process Map Decision point
Copy and use as needed
Notes
Delete these objects if they are not needed. (industrial) Insert any pictures on this worksheet. Steps within a Task
Drum
Step 1. Define el problema Cylinder

YES

Que Problema falla en modulo controlador de presion pfc 2000 en Pump

Process

Capture specifics about the problem as well as the impact to each

maquinas steelastic
Cuando Fecha NO
Valve
Tiempo 72 horas
of the organization's overall Goals. Donde
Diferente, inusual, unico
Instalacion, sitio STEELASTIC Exchanger

Unidad, area, equipo MAQUINAS STEELASTIC 1,2,3,4,5,6 Y 7

Tarea que se esta realizando revision del lazo de control

- Answer each question in the Outline. Impacto final

Seguridad N/A
Expander,
Turbine
Compressor

Use this box a picture label

Medio ambiente N/A
Cliente
Regulaciones
Produccion/programacion 8 horas
Propietario/equipo
Tabajo/tiempo Costo total
The sequence of events. Any diagrams, drawings or Any photos or images. The flow of any particular work Notes related to the
Este incidente sketches. process or task that is relevant to the investigation.
incident.
Frecuencia 3 eventos por mes
Costo anual $0

2 ...add as much detail as necessary to thoroughly explain the issue

Start with 3 to 5 Why questions (Causes)... Info To Get
Analysis Tool
Step 2 Step 2. Analysis Pos sible Solution: AND Why?
Effect Cause
OR Investigation Action List
Title Evidence: AND/OR Basic Cause-and-Effect Relationship This tab is used to track specific information gathering or support tasks for the investigation.
The 'Solutions' tab will capture the action items that are selected by the investigation team.
Cause Map

Lay out the cause-and-effect relationships for the incident.

No. Action Item Owner Date Created Due Date Status Completed
1
2
3
4
Im pact to AND 5

- Write down one of the Goals that was affected. Safety

Goal
6

AND

- Write the impact to that Goal in the next box. Any information gathering or support tasks
AND
required for the investigation.
- Answer the question "Why did that happen?" Ask Why again. Im pact to
Production
Goal

AND

- In the more detailed analysis, ask as many Why questions as Basic

necessary to thoroughly explain the issue. Detailed

Step 3 4

Solutions
Step 3
Propose Evaluate Create Each action item is a project.
Follow-up should evaluate effectiveness.
Possible Solutions Solution Options Action Plan
Identify the specific actions that will be taken to reduce the risk Based on causes identified in the analysis
Consider the Effort IN to the Solution Corrective Actions to be implemented

of a similar issue occurring. versus the Result OUT Since solutions control specific causes, every action item (solution) should correspond to a cause from the Cause Map. This provides continuity from the analysis to the action items.
step Only those causes with action items (solutions) are listed in this table.

- Place a possible solution above the cause that it controls.

Verification
Use: Convention, Industry Standards and The impact and No. Action Item Cause
Owner(s)
(Names)
Date Due
Status-
Completed
Notes (Check of

Creative Ideas risk to each Goal 1

effectiveness)

should be 2

- Evaluate the different possible solutions. reduced to an

3
4
5
acceptable level 6

- Create a plan for actions or a combination of actions that will 7

8

be implemented.
9
10

3
Project Charter - General Instructions: CCT Chenshan China
¥ CNY
CKT Kunshan China
¥ CNY V Lookup

Step 4
Cells for Project Champion to fill in. Cells for CPI, MBB's, BB's, GB's, Project Leads, or Finance to fill in. MS
Clarksdale $ USD Table
Findlay OH $ USD (to the
left)
- Worksheet/form is dynamic. Based on cell choices, form may change. Melksham UK £ GBP
- comments. <----cells like this provide comments or information. Mickey Thompson
$ USD
OH

Charter
Note:
- Access limited to input cells only. Worksheet is Read-Only. Re-name to save. Occidente Mexico
$ MXN Must be
- Print area set and formatted to fit on one page. Serbia RSD in
Shanghai Corp Of
¥ fCNY
ices alphabetic
Foreign currency (Mexico, UK, China, Serbia) - Financial Worksheet will convert amounts al order
Texarkana A R $ USD
to US dollars based on conversion rate entered.
Tupelo MS $ USD

CTLSS PROJECT CHARTER APPROVAL Doc #: OPEX-004

Issue Da te: 8/8/14
FORM Repl a ces: EtQDoc

CPI Review Date:

Project Title: ApprovedLink

by:to List of Approvers

Location: Pipeline Project #:

Develop CTLSS Charter Department:

Process Owner:
Assigned to a:
MBB, BB, GB, or YB
Finance Partner:
FP List Link
Master Black Belt:
Project Champion: Project Start Date:
Target Close Date:
Project Type:
Entered into PMAC? Yes or No

- Fill out CTLSS completely Opportunity Statement 1 Simply State your improvement opportunity (or pain) in one sentence.
Define Unit: 2 Units of measure for #3 (lbs, minutes, errors, tires, etc).
Define Metric: 3 What quantity can be measured that relates to your pain or customer requirement that is not being met? (must have units
Define Condition: 4 Describe the current state in terms of the defined metric (#3: What is the baseline?).
Project Objective: 5 Reduce or Improve (metric: #3) from (current state: #4) to (final value: metric target) by (date: target close date).
Upper Boundary (Start of
Process):
6 What starting point in the process will you be considering?

- Submit Charter to CTLSS BB.

Lower Boundary (End of
Process):
7 What ending point in the process will you be considering?
Historical Comments: 8 Add any supplemental information that will be useful.
Constraints: 9 Add any constraints that will need to be considered in working this project.

WORKING TEAM MEMBERS METRICS

Metric Unit of Metric Unit of Metric Unit of
Name Role Phone E-mail Goal
(1) Measure (2) Measure (3) Measure
Current
Target
Entitlement
Stretch

PROJECTED SAVINGS/BENEFITS
Hard Savings Soft Savings
OTHER SAVINGS Category Category WACC
Briefly Describe the expected project benefits. Include relevant calculations and explanations. Describe both the operational impact and the
Capital
financial impact from moving the primary metric (#6 above) from the baseline level to the target level per the objective. Sales 10.5%
Avoidance

Work.Cap
Material . 10.5%
Reduction

Cost
Labor N/A
Avoidance
Throughp
Scrap N/A
ut
Other - 1 Other - 1 10.5%
Other - 2 Other - 2 10.5%
Other - 3 Other - 3 10.5%
Hard Soft
Savings Savings

TOTAL
WA CC = Weighted A verage Cost of Capital
PROJECT

CONFIDENTIA L COMPETITIV E COMMERCIA L INFORMA TION: A ccess limited to authorized personnel. Copyright © Unpublished.
Step 1. Define el problema

Que Problema falla en modulo controlador de presion pfc 2000 en

maquinas steelastic
Cuando Fecha
Tiempo 72 horas
Diferente, inusual, unico
Donde Instalacion, sitio STEELASTIC
Unidad, area, equipo MAQUINAS STEELASTIC 1,2,3,4,5,6 Y 7
Tarea que se esta realizando revision del lazo de control
Impacto final
Seguridad N/A
Medio ambiente N/A
Cliente
Regulaciones
Produccion/programacion 8 horas
Propietario/equipo
Tabajo/tiempo Costo total
Este incidente
Frecuencia 3 eventos por mes
Costo anual $0
Step 2. Herramientas de analisis

no se tiene una
forma de se genero instructivo de revision de
evaluar el lazo de control y calibracion de
funcionamiento verificar el perfecto montaje al raz seguidor de presion de maquinas
entrada o salida de
de la salida y la del orificio que hace contacto con steelastic
control de seguidor
entrada de la camara de presion
de presion dañada
control del
seguidor de
presion

verificar el perfecto montaje al raz

del orificio que hace contacto con
la camara de presion

asegurar que exista un se genero instructivo de revision de

falla de modulo de procedimiento de revision de los lazo de control y calibracion de
presion PFC 2000 verificar que la
componentes involucrados en el seguidor de presion de maquinas
steelastic lazo de control del seguidor de steelastic
respuesta sea
presion
sensor dañado inmediata al
o mal montado oprimir area de
sensado del no se cuenta con un procedimiento
sensor de presion estandar de revicion o calibracion

ya se tiene la configuracion del

se desconoce la investigar la configuracion del cableado del sensor para revisar
configuracion del
cableado del sensor de presion punto a punto la integridad del
cableado de cableado
sensor dañado cableado del sensor

no se tiene un procedimiento de se genero instructivo de revision de

calibracion entendible solo pocas lazo de control y calibracion de
mala calibracion y personas conocen la forma correcta seguidor de presion de maquinas
sintonizacion de de calibrar este lazo de control steelastic
respuesta del lazo de
control
Step 4. Solutions
Corrective Actions to be implemented

Verification
Owner(s) Status-
No. Action Item Cause Date Due Notes (Check of
(Names) Completed
effectiveness)

generar instructivo de revicion

no se tiene el procedimiento
1 y calibracion de componentes Ruben diaz June 13, 2018 95% esta en revision
de calibracion
de lazo de control

investigar configuracion de
cableado de control de sensor no se tiene el pinout para la
2 agregarla al instrutivo de debida revision del cableado Ruben diaz June 13, 2018 100%
revicion y calibracion de lazo del sensor
de control

5
6
7
8
9
10
 Doc #: OPEX-004
CTLSS PROJECT CHARTER APPROVAL FORM Issue Date: 7/18/15
Replaces: 6/10/2015

CPI Review Date: 11/24/2017

Project Title: falla en controlador de precion PFC 2000 steelastic Approved by: Link: Who Should Approve My Charter? AZ

Location: Occidente Mexico

INTERNATIONAL Pipeline Project #: OC00587

Department: Prep Assigned to a: Green Belt

Green Belt Name: Ruben Diaz
Process Owner: Sergio Baltazar Green Belt Finance Partner (FP): Link: Who is my FP? Adriana Sanchez
Mentoring Black Belt: Adrian Zavala
Project Champion: Vicente Siso Project Start Date: 11/27/2017
Target Close Date: 12/29/2017
Project Type: PSR
Entered into PMAC? Yes or No Yes

Opportunity
There is an opportunity to reduce steelastics downtime by reducing the time to check calibrate and restart operation in case of
Statement
1 presure loop failure

time
Define Unit: 2

time to repair presure control loop

Define Metric: 3

Currently we have some events that takes more than 24 hours to repair presure control loop
Define Condition: 4

Reduce the time to repair presure control loop

Project Objective: 5

Upper Boundary
Extruder head is not controlling presure
(Start of Process):
6

Lower Boundary
Extrusion re starts correctly
(End of Process):
7

Historical
8
Comments:

Constraints: 9

WORKING TEAM MEMBERS METRICS

Metric Unit of Metric Unit of Metric Unit of
Name Role Phone E-mail Goal
(1) Measure (2) Measure (3) Measure
Current

Target

Entitlement

Stretch

Conversion Rate:

$ MXN to $ USD
PROJECTED SAVINGS/BENEFITS

Hard Savings Converted to USD Soft Savings Converted to USD

OTHER SAVINGS Category $ MXN Amount $ USD Category $ MXN Amount $ USD WACC
Briefly Describe the expected project benefits. Include relevant Capital
Sales - - 10.5%
calculations and explanations. Describe both the operational impact and Avoidance
the financial impact from moving the primary metric (#6 above) from the Work.Cap.
baseline level to the target level per the objective. Material - - 10.5%
Reduction
Cost
Labor - - N/A
Avoidance
Scrap - Throughput - N/A

Other - 1 - Other - 1 - 10.5%

Other - 2 - Other - 2 - 10.5%

Other - 3 - Other - 3 - 10.5%

Hard Soft
Savings Savings
$ MXN Amount $ USD
TOTAL WACC = Weighted Average Cost of Capital
PROJECT

CONFIDENTIAL COMPETITIVE COMMERCIAL INFORMATION: Access limited to authorized personnel. Copyright © Unpublished.
The controlled version of this document is electronically maintained.
 Timeline
event # Date Time Description
1 5/2/2018 24 hrs la maquina no controla la presion de extrusion del cablesillo
2 5/3/2018 24 hrs la maquina no controla la presion de extrusion del cablesillo se esta
trabajando en velocidad lenta
3 5/4/2018 24 hrs la maquina no controla la presion de extrusion del cablesillo se esta
trabajando en velocidad lenta
Diagram
Use the drawing tools to add any diagram to this worksheet. Example objects
Delete these objects if they are not needed. (industrial)
Cylinder Drum

Pump

Valve

Exchanger

Expander,
Compressor
Turbine
el sensor no esta montado de forma adecuada en ocaciones el area de contacto debe estar al raz de la pared de la camara de
presion como se muestra en la fotografia, debido a la vibracion natural del equipo se afloja y permea hule al interior generando
fallas en la medicion.

se saco la configuracion del cableado de control del seguidor de presion para ayudar al
diagnostico certero en caso de tener daño en cableados.

la presion de las pistolas de impacto no esta regulada correctamente

no existe un standar
Process Map Decision point
Copy and use as needed
Steps within a Task

YES

Process

NO
Notas finales
Operadores:
- Los operadores comentan las fallas en los controles de presion les ocacionan mucho desperdicio y aveves tardan varias
intervenciones en corregir de raiz

Mantenimiento:

- comenta mantenimiento que este problema es que los controles de presion no llegan bien reparados por parte del almacen

ATS :

ats mostro un reporte en el cual se descarta como principal problema las fallas en la reparacion de los modulos y se detectan
oportunidades de capacitacion al personal de mantenimiento en el cual los equipos reparados se regresaron a almacen con fallas de
puntos de calibracion perdidos.
 Investigation Action List

No. Action Item Owner Fecha inicio Fecha limite Estado Completado

1 investigar falta configuracion de cableado de sensor de presion DYNISCO r diaz 1-Jun-2018 1-Jun-2018 completado
realizar instructivo de calibracion y revision de componentes de lazo de
2 r diaz 1-Jun-2018 1-Jun-2018 completado
control de presion

871526435.xlsx Obtener informacion Page 15 of 18

Quick Access Toolbar
The Quick Access Toolbar, found along the top of the screen, is the only toolbar that you are able to customize. Add any command to the Quick
Access Toolbar by right clicking on the icon and then click Add to Quick Access Toolbar.

Arrow Cursor - Select Objects

The arrow cursor allows you to select drawing objects. The arrow cursor is located by clicking on Home from the menu bar. The last group on the
ribbon is called Editing. Inside of Editing is a Find & Select icon with a drop down. Click on Select Objects (the arrow) to select it.

Drawing Tools
To access the drawing tools ribbon you first must select (click on) an object, such as a text box, on the worksheet. Notice when you select an object a
new tab, Drawing Tools: Format, is immediately added to the end of the menu bar. When you click on either Format or Drawing Tools the ribbon
changes to a drawing tools ribbon. Remember you must have an object selected on the worksheet to access the Drawing Tools tab.

Working with Text Boxes

Clicking on text within a box highlights that box with clear dots on each corner and side and a dotted border. Clear dots show a cursor so that text
can be edited. Clicking directly on the border of the box will turn the dots blue and the border solid. Blue dots are for selecting the entire box.

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Copying Boxes
Left click directly on the border, hold the mouse down and drag the box to the desired location. Before releasing the left mouse button hold down
the Ctrl button on the keyboard. This is known as the Ctrl-Drag copy method.

Using Connectors
Use connectors to connect an object to another object. The connectors are located in the Insert tab in the Shapes drop-down menu. Click on the
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Connect two objects by clicking and holding the left mouse button at the beginning connection point and then moving the cursor to the ending
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Hold down the shift key and left click on the each object you wish to add to the selection. This multiple selection using the shift key works for
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Moving Boxes in a Straight Line

When moving a box hold down the shift key to move the box only at 90-degree angles: left, right, up or down. The shift button also works to copy
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CTLLS link: http://incoopernew/sites/QualityOpEx/CTLSS/Pages
Example of Failure Analysis Tools:
Fault Tree
Cause & Effect
Fishbone
FMEA
CTLSS/Pages/default.aspx