We all know, it isn’t exactly easy to identify the true cause of any process defect. Other than the assumption of “I know how to fix that,” too often significant changes are made without a just reason behind them when processes go awry. Every technician has a silver bullet that they believe is a better fix than the one provided by the previous shift. But, before making any major changes to your process, you should always consider the 5 M’s.
1.) MAN: Human error can be a major factor, and one of the easiest identify when a process is running in semi-automatic and the cycle time is dependent on the machine operator. Inconsistent cycle time can cause issues with material temperature and residence time
variations. This contributes to mold temperature inconsistency, not to mention lost productivity and increased scrap rate.
2.) MACHINE: Review actual readings on the machine and not the set points. Are the machine functions (hydraulic / temperature / time) functioning properly? Are the set points met in a normal response time? Once these have been checked, move on to the next M.
3.) METHOD: Is the machine set to the process set up sheet? Variations from the set-up sheet can have significant impacts on the process over even a short period of time. A process adjustment log is a great tool to have with the set-up sheet / book. Also, process deviations should not be allowed unless explicitly approved by the Process Manager and the book should be updated immediately after the process variation has been approved.
4.) MOLD: The mold should not be a factor if it is maintained, has had full PM’s performed at its scheduled intervals, and is within its life span of cycles produced. That being said, a tool that is not clean and venting properly will likely create problems. Identifying the problem area may require data to be collected over a period of time. Scatter / Concentration charts are very helpful in identifying where the problem originates.
5.) MATERIAL: Consider if the material changed recently. If this is in question, it is important to check the Certificate of Analysis that you should be receiving with incoming product.
By examining the 5 M’s, you should be well on your way to identifying the cause of your process defects.
Contact Rahco Rubber if you would like more recommendations on how to improve your process and reduce your defects. Will you continue to pay for your current supplier’s production downtime, scrap rates, or the uncertainty of the material being used? Or, work with Rahco where our goals are zero defects, zero scrap, and zero downtime.