Troubleshooting Basics, part two

In part one, we discussed the defining of the problem and the thought process behind it. We could have given a listing of problems based on troubleshooting guides but there again, we want the thought or learning process to go on. We now come to the second part of the process and that is the PLAN.  What are the steps we will take to solve
the problem?

Given that we defined the problem, it could be as simple as picking up a trouble-shooting guide and going though the checklist given. Butt in most cases when we go to define the problem a plan starts to assemble as we go through the defining process. The real problem with the plan is what to do first and in what order. For example, let us go back to the problem of not enough material in the part giving the result of shorts. Looking short shots up in the books you could find anything form adding pressure, injection forward time, increase stock temperature, etc.  The plan is to start with the simplest observation, and those that do not require the raising or lowering of temperature as these usually take the longest to get done on a time basis. Thus since we determine the parts are short, we need check the basics:
A) What is the stock temperature and is it at recommended range?
B) How much of the part are we filling on first stage or fill?
C) What is the mold temperature?  Not what the thermulator is but steel temperature
D) Is the fill time consistent?
E) If the problem is inconsistent is the process also inconsistent.
F) Machine setup; how does it match the master in setup scope?
G) What's the material, regrind, color, drying, if so how etc.

Though these are not listed in any particular order, they may be things that you list in a sheet that states check this this and this in a set order. The plan is now to determine why the problem exists and solve it, the why. The steps taken can be a cause and effect approach, or where are we. This may be included in the definition stage or determination stage of what caused the problem.
The plan should be stated "steps to be taken to determine the cause of the problem and apply a solution".  With out a plan we may or may-not determine a solution. Stated again time is money and in most cases someone will apply the twist of the knob or impute to the computer and the problem goes away, for the time being.  If the same problem
comes back than maybe the solution was not correct.  Remember there are many solutions to the same problem listed in the guides. The key is determining, which is right for your problem and learning from it. The suggestion made to create your checklist of things to check and place on the machine may be the first step to accomplish the correct plan. This than gives a step by step approach, which depending on the operation can be simple or elaborate but in either case gives data to back up the solution applied.

Thanks for the time, to be continued.

Steven L Silvey
Senior Technical Service
General Polymers Division of Ashland Distribution