Ishikawa Diagram - Questions To Be Asked While Building A Fishbone Diagram

Questions To Be Asked While Building A Fishbone Diagram

Man/Operator – Was the document properly interpreted? – Was the information properly circulated to all the functions? – Did the recipient understand the information? – Was the proper training to perform the task administered to the person? – Was too much judgment required to perform the task? – Were guidelines for judgment available? – Did the environment influence the actions of the individual? – Are there distractions in the workplace? – Is fatigue a mitigating factor? - Is his work efficiency acceptable? - Is he responsible/accountable? - Is he qualified? - Is he experienced? - Is he medically fit and healthy? – How much experience does the individual have in performing this task? - can he carry out the operation without error?

Machines – Was the correct tool/tooling used? - Does it meet production requirements? - Does it meet process capabilities? – Are files saved with the correct extension to the correct location? – Is the equipment affected by the environment? – Is the equipment being properly maintained (i.e., daily/weekly/monthly preventative maintenance schedule) – Does the software or hardware need to be updated? – Does the equipment or software have the features to support our needs/usage? - Was the machine properly maintained? – Was the machine properly programmed? – Is the tooling/fixturing adequate for the job? – Does the machine have an adequate guard? – Was the equipment used within its capabilities and limitations? – Are all controls including emergency stop button clearly labeled and/or color coded or size differentiated? – Is the equipment the right application for the given job?

Measurement – Does the gauge have a valid calibration date? – Was the proper gauge used to measure the part, process, chemical, compound, etc.? – Was a gauge capability study ever performed? - Do measurements vary significantly from operator to operator? - Do operators have a tough time using the prescribed gauge? - Is the gauge fixturing adequate? – Does the gauge have proper measurement resolution? – Did the environment influence the measurements taken?

Material (Includes Raw Material, Consumables and Information ) – Is all needed information available and accurate? – Can information be verified or cross-checked? – Has any information changed recently / do we have a way of keeping the information up to date? – What happens if we don't have all of the information we need? – Is a Material Safety Data Sheet (MSDS) readily available? – Was the material properly tested? – Was the material substituted? – Is the supplier’s process defined and controlled? - Was the raw material defective? - was the raw material the wrong type for the job? – Were quality requirements adequate for the part's function? – Was the material contaminated? – Was the material handled properly (stored, dispensed, used & disposed)?

Method – Was the canister, barrel, etc. labeled properly? – Were the workers trained properly in the procedure? – Was the testing performed statistically significant? – Was data tested for true root cause? – How many “if necessary” and “approximately” phrases are found in this process? – Was this a process generated by an Integrated Product Development (IPD) Team? – Did the IPD Team employ Design for Environmental (DFE) principles? – Has a capability study ever been performed for this process? – Is the process under Statistical Process Control (SPC)? – Are the work instructions clearly written? – Are mistake-proofing devices/techniques employed? – Are the work instructions complete? - Is the work standard upgraded and to current revision? – Is the tooling adequately designed and controlled? – Is handling/packaging adequately specified? – Was the process changed? – Was the design changed? - Are the lighting and ventilation adequate? – Was a process Failure Modes Effects Analysis (FMEA) ever performed? – Was adequate sampling done? – Are features of the process critical to safety clearly spelled out to the Operator?

Environment – Is the process affected by temperature changes over the course of a day? – Is the process affected by humidity, vibration, noise, lighting, etc.? – Does the process run in a controlled environment? – Are associates distracted by noise, uncomfortable temperatures, fluorescent lighting, etc.?

Management - Is management involvement seen? – Inattention to task – Task hazards not guarded properly – Other (horseplay, inattention....) – Stress demands – Lack of Process – Training or education lacking – Poor employee involvement – Poor recognition of hazard – Previously identified hazards were not eliminated