Machine Monitors - What is a Malfunction? Example
#1
A
malfunction in an automated machine is any interruption caused by jamming,
stops and restarts, operator error, process failure, or bad raw material.
Malfunctions cause defects.
Malfunctions are difficult to describe in words.
By nature, they are often intermittent and unpredictable. Since you never know
when a malfunction will occur, they are tough to spot.
Malfunction Questions:
Definition - Anything that interrupts the
normal operation of an automated machine.
When a machine breaks, the decision is clear. Repair the machine.
But, what about when a jam
occurs and the machine is restarted?
Have you ever operated a machine
that stops frequently?
Were you able to explain what
happened?
What was the root cause of the
problem?
Very often operators and maintenance personnel
are aware of malfunctions but feel powerless to solve them. After a while they "learn to
live with it." This means they have to pay attention to the
production line all the time just in case something goes wrong. A waste of
effort.
Below is a 30 second video clip. This may take 5 seconds to load.
Can you spot the malfunction?
With Machine Monitor, we offer you the ability to
identify and document malfunctions on video. Once the information is
collected you can share it with everyone.
The example above is from an automated
machine that makes light filaments. The malfunction occurs 20
seconds into the video clip. Malfunctions like to this cost your business money,
especially when thousands of units are processed each day. If missed on
inspection, the filament could get into the hands of a customer.
The customer, dissatisfied with the filament, has to return it. They have
to find the receipt, drive back to the store, exchange it, then drive home
and install the new one. A very poor buying experience.
When you can pin point the root cause
of a defect, it is usually some small overlooked detail on the production line.
It could an operator error, a maintenance adjustment, or complex engineering
problem. Eliminating defects is an essential part of
running a profitable production line.
Malfunctions = Defects
Less Malfunctions = Less Defects
= More Revenue
The
Solution - Machine Monitor™
A Machine Monitor can show you exactly what a malfunction looks like.
You no longer have to stand and watch your production line waiting for the
problem to recur. You don't have to ask the operator or maintenance or
anybody for information about problems on your production line.
Why guess at
the problem? You will likely make a mistake. With a Machine Monitor, you will know
exactly what is going on and have
the capability to share the information with anyone. (See
Email a Video Clip.)
Once the malfunction is corrected, the
company saves time and money. Not to mention frustration for the customer,
your management, engineers, maintenance crews,
quality inspectors, and even the operators. Imagine how relieved
everyone will be when all your malfunctions are gone.
A
malfunction in an automated machine is any interruption caused by jamming,
stops and restarts, operator error, process failure, or bad raw material.
Malfunctions cause defects.