Troubleshooting: Problem Solving Strategies 178

ammonia

A colorless, strong-smelling gas. Ammonia is toxic, corrosive, and flammable.

Automated

Performed without human intervention or involvement. Automated manufacturing systems make use of computer systems to control various machine tools and manufacturing components.

batteries

A device that converts chemical energy into electrical energy. Batteries are a source of direct current.

Chatter

Vibrations of the cutting tool during machining. Chatter causes surface imperfections on the workpiece and increases tool wear.

chemicals

Any element, compound, or mixture of elements and/or compounds. Chemicals may be solids, liquids, or gases.

circuits

A controlled path for electricity. A circuit includes a source, path, load, and control.

Computer numerical control machines

CNC machines. A machine controlled by a computer that runs special programs to manufacture a workpiece. Computer numerical control machines require an operator for setup, but the machine movement is controlled by a computer.

cutting fluid

A liquid used during cutting operations to reduce heat and friction between the cutting tool and the workpiece. Cutting fluid may contain oil or other flammable liquids and is a potential fire hazard if disposed of improperly.

Cutting inserts

A replaceable cutting bit or edge. Cutting inserts are often made from carbide.

cutting tool

A device with one or more edges that is designed to cut metal. Cutting tools are often designed to be used on a machine tool such as a mill or lathe.

Data

A collection of numbers, facts, and information about a process or product. Data can be created, communicated, and recorded by sensors in smart objects.

de-energizing

Removing all stored energy in a machine or system. De-energizing may involve removing electrical, mechanical, hydraulic, or pneumatic energy.

defective

Not meeting required quality and performance specifications. Defective parts must be repaired or replaced.

Diagnostic

A set of computer instructions used to investigate and analyze the cause or nature of errors or failures. Diagnostics can help technicians troubleshoot a problem quickly.

digital

Consisting of information that is input or output electronically as a series of pulses or signals, often resulting in binary strings of 0s and 1s. Digital computing devices interpret various programming commands as binary digits.

Direct cause

The incident or condition that directly creates a problem. Direct causes, also called immediate causes, are usually symptoms of the root cause.

documentation

Information that is collected, stored, and used to monitor and improve safety, quality, and efficiency. Documentation may include machine manuals, maintenance records, process descriptions, and safety incident logs.

downtime

A period of time when a machine or a facility is neither operating nor producing. Downtime should be avoided whenever possible.

Electric current

The flow of charged particles. Electric current can be measured with a multimeter.

Emergency Action Plan

EAP. A written document detailing procedures to follow during an emergency. An emergency action plan should include evacuation, critical shutdown, and emergency reporting procedures, as well as instructions for accounting for personnel, performing rescue operations, and providing medical assistance.

Error codes

An alphanumeric message that references a specific cause of malfunction. Error codes appear on the machine interface and can be cross-referenced in the manual.

error proofing devices

Any tool or process used to reduce or eliminate errors from a manufacturing process. Error devices might use alert lights or other means to signal that a problem has occurred.

Fire Prevention Plan

FPP. A set of proactive procedures implemented to avoid fires in the workplace. Fire prevention plans include a list of all fire hazards, the types of fire protection equipment needed to control these hazards, and other precautions.

flammable

Capable of easily and quickly catching fire. Flammable items ignite at low temperatures.

half-split method

A troubleshooting strategy that involves repeatedly dividing a system in half in order to find a malfunctioning component. The half-split method, also known as the split-half method, is commonly used for troubleshooting electrical circuits.

Hazard Communication Standard

HCS. An established OSHA policy that sets guidelines for hazard communication. The Hazard Communication Standard emphasizes labeling, Safety Data Sheets, and employee training.

Hydraulic

A form of fluid dynamics that uses the motion and pressure of liquids to create power. Hydraulic power uses cylinders and pistons to convert the flow of liquids into mechanical energy.

Hypothesis

A proposed explanation for the cause of a problem. A hypothesis must be tested to see whether or not it is correct.

Immediate cause

The incident or condition that directly creates a problem. Immediate causes, also called direct causes, are usually symptoms of the root cause.

Indirect cause

An incident or condition that creates effects which eventually lead to a problem. Indirect causes come between the root cause and the direct cause.

Infrared

Invisible rays of light energy emitted by heated objects. Infrared light is invisible to human eyes but can be detected by specialized sensors.

interlock

A safeguarding device that prevents a machine from operating when it is out of position or when a different operation is taking place. Interlocks help to prevent injury during operation.

irritants

A chemical that causes inflammation or other reversible damage to human tissue. An irritant usually causes short-term effects.

Known good state

A previous configuration of a system where it functioned without problems. Resetting a system to a known good state can fix problems introduced by updates or changes.

lockout/tagout

A method of protecting employees from accidental machine startup by locking and labeling devices. Lockout/tagout renders a tool or machine inoperable.

machine guards

A rigid shield or cover that encloses hazardous areas on a machine. Machine guards prevent accidental machine contact with body parts and prevent debris, such as chips, from exiting the machine.

Occupational Safety and Health Administration

OSHA. A government agency that sets the standards for working conditions in the United States. The Occupational Safety and Health Administration ensures that employees work in safe and healthy environments.

OEM

Original equipment manufacturer. An organization that provides parts and equipment to the supply chain. OEMs supply parts and equipment to other manufacturers that use them in finished products.

original equipment manufacturer

OEM. An organization that provides parts and equipment to the supply chain. Original equipment manufacturers supply parts and equipment to other manufacturers that use them in finished products.

overall equipment effectiveness

OEE. A lean metric that measures how effectively equipment is being used. Overall equipment effectiveness is determined by multiplying the percentage of an equipment's availability, quality, and performance together.

personal protective equipment

PPE. An article of clothing or a device worn to minimize exposure to hazards and prevent injury. Personal protective equipment may include safety glasses, safety gloves, ear plugs, respirators, or steel-toed boots.

Pressure

A measurement of the amount of force exerted on a surface divided by the area of the surface. Pressure is typically expressed in pounds per square inch (psi).

process of elimination

A logical method of removing incorrect options until only the correct option is left. Processes of elimination are used to create and test hypotheses for troubleshooting.

program

A computer-based series of commands that contains all pertinent instructions and information for the completion of a specific task. Programs are used by CNC machines, PLCs, and robots.

Programming

The process of entering digital information into a computer or computerized system. Programming involves the use of a machine interface and a programming language that can tell the machine what actions to perform.

recall alert

A communication issued when a product fails to meet minimum safety standards or is found to be an unreasonable safety risk. Recall alerts inform customers that the products they purchased should be returned, repaired, or retired.

Robots

A mechanical device that can be programmed to perform a variety of complicated, repetitive tasks. Robots are used to automate manufacturing and inspection processes.

Root cause

The true origin of a problem. Identifying the root cause of a problem helps to create permanent solutions.

root cause analysis

A study to determine the first or underlying cause of a problem. Root cause analysis involves the collection and study of data to determine the true cause of a problem.

routine maintenance

Maintenance that is performed at regular intervals. Routine maintenance tasks include lubricating, tightening, and replacing parts.

Safety Data Sheet

SDS. A mandatory document containing hazard information that must accompany almost every chemical in the workplace. A Safety Data Sheet consists of several sections that detail information such as the hazards, precautions, and first aid procedures associated with the chemical.

scrapped

Discarded or otherwise destroyed. Parts must be scrapped if they do not meet specifications.

Sensors

A device that detects a change in a physical stimulus and turns it into a signal that can be measured or recorded. Sensors may be connected to a machine or system in order to collect operational data that is later analyzed.

Sequence

In a specific order where one thing happens after another. An assembly line is an example of a process that happens in sequence.

service life

The length of time a component or device is expected to be in operation before needing to be replaced. Service life can be increased by performing regular maintenance.

setup

All of the tasks and preparations necessary to prepare for a machining operation. Setup can include preparing machines as well as collecting paperwork, tools, and materials.

smart manufacturing

Technologically integrated manufacturing that creates and uses data in real time to address the needs of the factory, supplier, and customer. Smart manufacturing is an advancement of traditional manufacturing automation.

Software

A set of digitized programs and operating procedures. Software determines the actions or performance of a computer or machine.

Software updates

The latest version of a software package that is typically installed through an internet connection. Software updates often include security patches and improvements in function.

Spindle speed

The rate at which the machine spindle rotates. Spindle speed is typically measured in revolutions per minute (rpm).

Split-half method

A troubleshooting strategy that involves repeatedly dividing a system in half in order to find a malfunctioning component. The split-half method, also known as the half-split method, is commonly used for troubleshooting electrical circuits.

Technical support

Assistance provided by those with product and system knowledge to solve customer problems, identify optimal solutions, or provide information about product use. Technical support is usually available by phone or through online channels for some manufacturers.

Temperature

A measurement of the amount of thermal energy in a substance. Temperature is measured in degrees.

tool wear

The erosion of tool material as a result of friction. Tool wear degrades the accuracy and precision of a tool.

troubleshooting

A systematic approach to solving problems quickly and efficiently. Troubleshooting often involves a logical process of elimination to identify the source of a problem.

Turning center

A sophisticated computer numerical control (CNC) lathe that can perform multiple operations. Turning centers specialize in turning, boring, drilling, and threading operations.

Ultrasonic

Above the range of human hearing. Ultrasonic sounds can be detected by acoustic monitoring.

Vibrations

A rapid continued, repeated motion in a machine or other structures. Vibration can negatively affect mechanical operations.

visual inspection

An assessment where an operator examines a tool, machine, or part for defects or wear without the use of an assistive device. Visual inspection is sometimes supplemented with mechanically-assisted inspection.

waste

A lean manufacturing concept that includes any thing or process that does not add value to a product. Common forms of waste include scrap and unnecessary machine downtime.

work cell

An arrangement of machines, tooling, materials, and operators structured around the design of similar products. Work cells encourage smooth product flows and use space efficiently.