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Definition: Troubleshooting: the process of resolving issues and or causes to defects. Documentation: collecting, recording, and dissemination of specialized knowledge. Utilization: to put to use; turn to profitable account.
While taking the time to research and solve an issue with a mold and or machine in processing the effort and results are not valuable unless documented and then recorded for future use. This data information cannot reside only in the processors back pocket or other location but must be shared and posted.
While implementing the plan of attack on the mould/process to find a solution to an issue/opportunity both what was tried/changed and the results of the change should hopefully have been recorded. This possibly was done in rough form or with newer technology within a software system in plant. Not only are the solutions recorded but also the failures or non-solutions which were tried.
The issue now becomes what is to be done with this information. While in most plants it disappears, it should result in a troubleshooting guide for this mould/process. What is meant is that an issue was found, steps were taken to find a solution and the solution was implemented. The good parts yielded show that the solution did/does work thus why it should be recorded. This recoded data than leads to instructions for this issue so as to how to solve.
Thus as with all trouble shooting guides: there is an issue and there are solutions. So for this mould/process we may insert within instructions or for troubleshooting said problem the steps to take to resolve this problem. If more than one solution was found than provide both and possibly list in order of success, or which would be the first to try and then the second and third etc... This documentation would than stay with this mold and its setup sheet so as to be available to all.
Within the mold setup there would now be a troubleshooting guide and or problems sections which would list issues that occur with mold/process for these parts. Since the setup follows the mold to the press it is always handy to have. It than also becomes a living document as new issues arise and or new solutions to existing issues comes about.
Additionally this information should be stored in a master guide. The guide may be broken into multiple sections and or chapters dependent on how the organizations wish to set it up.
One such way may be by issues, thus black specs, streaking, white marks, part breakage etc... An additional way may be by materials being processed, thus Nylons may have a section and ABS, PC and so forth. These headings than would have subsections for the problems i.e. black specs, streaking, etc.
Reviewing the numerous troubleshooting guides and formats out there may provide and or help in creating or even just purchasing these to post in your plant or system.
If creating your own a spread sheet program for example ExcelŽ may be a start. This could be done multiple ways.
One way is to list the issues down the left hand column and then list solutions or area to try across the top row. Within the field would be an arrow with a number inside it, which would be what to try first, second 3rd , etc. and the arrow points either up or down so as to show which way to go.
The above are just examples for clarification as to how to format, which would place the number inside the arrow or possible different colors as to 1st, 2nd, 3rd etc. to try to resolve the issue as listed in left hand column
Another possible way by use of a spread sheet is to detail it out by machine / mold / material as the following illustrates:
The above is just an example taken from an old Monsanto guide for ABS. With it there was no first this than this only a listing of things that are causing the issue thus one could use it as a guide to try to lower of increase or change things per the statement to resolve the issue presented.
The reason for the above is twofold. One is that internally a list of cause and effects are being generated with the solutions, by the defect which is spread across all materials. Secondary it is also by individual materials.
While creation of the indexes is time consuming and someone has to create it, it is a work in process and an aid to those on the floor trying to resolve issues. It creates a library / reference for solutions to issues, which dependent on the plants product may become invaluable, both I short term for solving production issues but also long term in design and building of new tools which possibly include solutions to issues with previous tools.
SLSILVEY
19092013
ExcelŽ is a registered trademark of the Microsoft Corporation.
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