Troubleshooting Coating Defects 170

5 ME

A term used to describe the six main causes of problems: man, method, machine, material, measurement, and environment. 5 ME is often used to organize the parts of a fishbone diagram.

80-20 rule

A principle stating that, in general, 80% of problems arise from 20% of causes. Pareto charts are often used to demonstrate the 80-20 rule.

analytical data

Information obtained by breaking down a coating process into its individual parts and comparing these parts to the finished coating. Analytical data is gathered by physically examining each aspect of a process.

blister

A small, dome-like bulge in the coating film or a small recess in a coating film. Typically blisters are caused by trapped moisture, rapid drying, and the use of improper solvents.

brainstorming

An activity in which an individual or group rapidly lists ideas, problems, or solutions. Brainstorming can be used in the troubleshooting process to identify possible problem causes or to form hypotheses.

breakpoint

The point at which the slope of the line on a Pareto chart becomes much less steep. This point indicates that the problems to the right of the point are much less frequent than those on the left.

cause and effect diagram

A fishbone diagram. A graphical tool used to identify and isolate potential causes of any defect.

check sheet

A visual tool for tracking data and making decisions by placing tic marks into different cells to create a graphical representation of the data being tracked.

defect

An irregularity in the specified and expected finish of a part. Typically, a coating defect either negatively impacts a coating's aesthetic appeal or impairs a coating's functionality.

deviation

A situation that is less than ideal but is temporarily acceptable. A coating with bubbles that do not affect its quality or performance is an example of a deviation.

downtime

Unproductive blocks of time during which machine operations cease, often due to mechanical problems. Downtime raises a company’s financial costs, which leads to financial losses.

environment

In 5 ME, the factor that represents the potential for error due to the surrounding area in which the process occurs. This and other factors in 5 ME are often organized in a fishbone diagram.

fishbone diagram

A cause and effect diagram. A graphical tool used to identify and isolate potential causes of any defect.

hypothesis

A tentative guess that is based on observation and that can be tested through further observation and research.

initial name syndrome

The process of addressing an indirect cause and consequently taking an inappropriate course of action to remedy a defect resulting from incorrectly naming the defect. Initial name syndrome often occurs when a particular defect is named before being properly defined.

inspection

The examination of a part to determine if it meets specifications. Coating inspection can occur during or after coating application.

machine

In 5 ME, the factor that represents the potential for error due to equipment performance. This and other factors in 5 ME are often organized in a fishbone diagram.

man

In 5 ME, the factor that represents the potential for human error. This and other factors in 5 ME are often organized in a fishbone diagram.

material

In 5 ME, the factor that represents the potential for error due to quality problems with stock or other items used in a process. This and other factors in 5 ME are often organized in a fishbone diagram.

measurement

In 5 ME, the factor that represents the potential for error due to problems with certain instruments. This and other factors in 5 ME are often organized in a fishbone diagram.

method

In 5 ME, the factor that represents the potential for error due to incorrect or outdated instructions and practices. This and other factors in 5 ME are often organized in a fishbone diagram.

optical inspection

A method of inspection that uses sight, light, and magnification to inspect the features of a part. Automated optical inspection machines reduce the chances of human error.

Pareto chart

A visual tool used to identify the causes of problems that occur most frequently. Pareto charts are often used to demonstrate the 80-20 rule.

predictive maintenance

A maintenance approach that involves testing and monitoring machines in order to predict machine failures.

problem

A situation that is unacceptable and must be corrected, in many cases as soon as possible. A coating that does not meet quality demands is an example of a problem.

problem statement

A description of the issues that need to be addressed. Defining a coating defect enables the formation of a problem statement.

process control

A method of checking product performance and batch consistency by regularly measuring and regulating processes that yield a product. Coating companies often seek to prevent coating defects through effective process control systems.

process information

Data regarding each process used to prepare and make a part. Both qualitative data and quantitative data are collected when gathering process information.

production run

The collective processes that are necessary to manufacture a group of similar or related parts. During troubleshooting, trial production runs are performed to test solutions.

qualitative data

Descriptive information about a part or process. Qualitative data is subjective information that usually is not measured.

quantitative data

Information that is measured and recorded. Quantitative data is objective information and is usually a number.

real time inspection

An inspection technique that involves examining a coating during each stage of its process, from surface pretreatment through application and curing.

root cause

The true origin of a problem as opposed to the symptom of a prior cause. Troubleshooting focuses on identifying the root cause of a problem rather than simply addressing the symptoms.

standard operating conditions

The environment in which production runs normally occur. Trial production runs must be performed under standard operating conditions to test solutions to problems in a process.

standard operating procedure

A document describing an organization's model processes. It contains a moderate amount of detail about the techniques and equipment used in the process.

troubleshooting

A systematic approach to solving problems quickly and efficiently. Troubleshooting focuses on identifying the root cause of a problem and fixing that cause.

visual inspection

A routine stage of a finishing operation that involves closely examining a part with the naked eye immediately following its production to check for defects.