Step 1: Identify the fault phenomenon.

Correctly understanding the fault phenomenon is the premise to solve the fault problem. Understand and analyze the manifestation, state, location and equipment type differences of fault phenomena.

And the fault is analyzed hierarchically.

When exploring and investigating fault phenomena, we should pay attention to research methods, determine relevant investigation, determination, inspection and analysis methods according to the phenomenon research, and determine investigation items, detection scope, tolerance, benchmarks and limits.

Step 2: Physical analysis and principle analysis of fault phenomena.

The so-called physical analysis of phenomena is to analyze phenomena by exploring the principles in physics and chemistry.

Any fault phenomenon will not happen for no reason, but has its physical or chemical background. Therefore, we should try to explain the fault phenomenon with the scientific principles of physics or chemistry. It would be better if it could be supplemented by physical and chemical tests. Try to find out the physical and chemical principles of the fault phenomenon.

For example, if there is an axial crack in the spindle of a machine tool, it can be found through metallographic examination whether it is a raw material defect or a heat treatment stress or a fatigue stress concentration.

Another example: object scarring is a phenomenon caused by contact and impact between objects. From a physical point of view, scars must appear in the weak parts of the object. In this way, by discussing the possible contact parts between objects, we can clearly know the parts to be discussed and the reasons for the phenomenon.

If you really can't explain the phenomenon, you can make assumptions to verify it.

Why should we analyze the principles of physical chemistry? Consider and expand the problem theoretically, without missing factors, and explain it systematically. It can prevent frequent subjective judgment. Although many measures have been taken, the reasons, measures and management points of no countermeasures to reduce long-term losses can be fundamentally modified.

Step 3: Conditions for the failure phenomenon to be established

According to the scientific principles and laws, the conditions for the popularization of this phenomenon are discussed. By exhaustive method, the conditions contributing to this phenomenon are listed as much as possible, regardless of its probability, and then analyzed and screened.

This paper discusses the conditions of the phenomenon from the perspective of principles and principles. If such conditions are met, phenomena will certainly occur, and sorting them out is the key to solving the problem. It is necessary to analyze this phenomenon from the perspective of physics and explain its mechanism and conditions.

Generally, the conditions for the establishment of the phenomenon are not fully grasped. When taking countermeasures, only some conditions can be considered and countermeasures can be taken, and other conditions are not considered. Therefore, chronic losses often do not decrease. At the same time, we should also pay attention to various conditions for establishment. Regardless of probability.

Step 4: Discuss the reasons for failure from multiple angles.

Find the cause of the failure from the five elements of the production site (machines, tools, materials, methods, environment and operators). List the reasons related to the fault phenomenon, screen out the most relevant factors from people, machines, things, laws and environments, put forward all the factors that can be considered, and draw a causal relationship diagram.

It is important to discuss the subdivision of equipment into parts. Sometimes, various reasons will repeatedly affect their respective submission conditions.

Step 5: Determine the main reason.

Some of the reasons listed in the previous step may not be the main reasons. This step is to verify (investigate, check and analyze) the causes of various failures and find out the main causes of failure phenomena.

Due to various reasons, it is necessary to study different verification methods, investigation methods, judgment methods, investigation scope, judgment methods of standard surfaces, investigation items, etc. If there is a deviation between the investigation method and the factors to be investigated, the results of verification will not be trusted by others, and the reasons found are not the main reasons, then the future solutions will be invalid.

Step 6: Propose an improvement plan.

According to the verified causes of various faults, the improvement scheme is put forward.

According to the mastered tools, means and methods, determine how to solve the problem or improve it.

After the measures are formulated, they should be implemented. Aiming at the fault point, the countermeasures are made clear and the improvement is implemented to make its equipment more perfect.

In the process of implementing improvement, records should be made.