Dealing with problems in a factory can be challenging.
Production lines and automated machines generally do not run perfect most of the
time. The best way to deal with these problems is the Trial and Error
Method. He is how it works in a factory on automated production lines.
First, you talk to some people in the plant and develop a theory
as to why a particular problem exists. Take a piece of
paper around to the operators and maintenance people. Have them write down
comments about the problem. What the root cause might be or maybe suggest
how to fix the problem.
In order to get a better idea of what I mean, here are some common
examples I have run across in my career.
1. This machine does not start-up/ramp-down properly.
2. Every once in a while the machine jams. Here is
what I think happens.
3. The machine breaks down daily and is not reliable.
Seal failure, belt failure, gear box etc.
Document your changes
After you have talked to several people and you fully understand
the problem. You then make your move and fix something on the machine.
It is best to wait until the machine is shut down. Because when you take
the machine apart, often you realize you need more time to get the right parts.
You can
1. Adjust the PLC program. Change the electrical
wiring. Adjust internal timers and counters.
2. Change tooling, change the machine mechanically, or beef up
weak structures.
Whatever changes you make, be sure to document what you are
doing. Write it down. You need to be able to change it back
if your fix does not work. If the machine stops working after you fix it you are
looking at write up from management.
The next thing you do is start up the machine and watch it
closely. Be patient and wait to see the result. If the fix worked,
you can stop right there. If it "sort of" worked you will learn something.
If it doesn't work you at all, you must change it back immediately and get the machine running again.
Start over with what you've learned and think of
another way to solve the problem. Nobody likes to be handed a downtime
situation.
The trial and error method is very low cost. It works most
of the time on the first try if you plan ahead and ask around.
What is the alternative? Live with the problem?
Can your business really afford that?
The trial and error method is the best way to get process
improvement and it is worth the effort.
>>>Are you a plant manager or engineer? Is downtime keeping
you up at night? Gather precise information about your production line
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