Last updated on 2024年7月18日

Here's how you can analyze and troubleshoot problems in manufacturing.

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Manufacturing is a complex field that demands precision, efficiency, and a keen eye for detail. When problems arise, it's essential to have a systematic approach to analyze and troubleshoot them. Whether you're dealing with a sudden drop in product quality, a bottleneck in production, or equipment failures, understanding the root cause is critical. You can turn disruptions into opportunities for improvement by applying problem-solving skills and knowledge of manufacturing processes. This article will guide you through the steps to effectively identify and solve manufacturing challenges.

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Gerry Lo

Retired
Mehrdad Nouri

Head Of Warehouse at Isaco
Fábio M. Ferreira Moreira

Regional Quality Engineer KAEA | Project Management | Quality Management | VDA 6.3 Certified | VDA FMEA & Reverse FMEA…

1 Identify Issues

To effectively troubleshoot in manufacturing, start by identifying the issues clearly . This involves observing the symptoms of the problem, such as defects in the final product, machinery malfunctions, or unexplained delays in the production line. You should document these symptoms meticulously, noting when and where they occur. This initial step is crucial because it sets the stage for a thorough investigation. Without a clear understanding of what's going wrong, it's nearly impossible to develop an effective solution.

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Qassim Abdul Hameed Padela

Operations Improvement Consultant Project Manager Textiles, fresh manufacture, stocklots, excess inventory Automobiles & General Trading Parts Fabrication
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Find out: ? Why did the problem occur? ? What caused the problem? After the problem has been identified: ? Rectify the problem, be it mechanical, human or system related ? Implement a system to prevent the same problem from recurring

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Fábio M. Ferreira Moreira

Regional Quality Engineer KAEA | Project Management | Quality Management | VDA 6.3 Certified | VDA FMEA & Reverse FMEA | Master’s in Chemical Engineering | Process Optimization | Data Analysis |
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There are multiple ways you can start in order to identify issues. The most important thing to keep in mind is to correctly define and understand the problem. As Albert Einstein said "If I had an hour to solve a problem I'd spend 55 minutes thinking about the problem and five minutes thinking about solutions". 1. Start by doing a simple "5 W's & 2 How to better define the issue. 2. Review the "Checklist before start production" to see any point was actually NOK. 3. Perform a simple 5 Why's ( Why did it occur ?) and also very important (Why was not detected ?). This should be a great starting point to help further down in the line, solving whatever its needed.

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2 Gather Data

Once you've identified the issues, the next step is to gather relevant data. This includes production metrics , machine performance records , and quality control reports . Analyzing this data can reveal patterns or anomalies that may point to the source of the problem. It's important to approach this step without bias; let the data guide your analysis rather than trying to fit the data into preconceived notions about what might be wrong.

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Mehrdad Nouri

Head Of Warehouse at Isaco
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Obviously for starting an analysis we need to gather data in essential processes then identify bottlenecks and refine them. Definition a suitable KPI can be effective.

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Fábio M. Ferreira Moreira

Regional Quality Engineer KAEA | Project Management | Quality Management | VDA 6.3 Certified | VDA FMEA & Reverse FMEA | Master’s in Chemical Engineering | Process Optimization | Data Analysis |
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Before gather data, you must understand which data you need. If you follow the point 1. mentioned prior, you will have the information regarding when it happened and who detected. 1.Identify the relevant data and also, identify the exact moment when the issue occur. 2. Collect data in a timeline where you can see records prior to issue occur, when the issue happened and also afterwards. (That way, you will have a complete overview of, how your process was affected and the consequences)

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3 Analyze Patterns

After collecting data, you need to analyze it for patterns that could indicate the root cause of the problem. Look for correlations between different variables, such as an increase in defects when a particular machine is in use or during certain shifts. This step often involves using problem-solving methodologies like root cause analysis or the "Five Whys" technique, which involves asking "why" repeatedly until you reach the fundamental cause of an issue.

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Fábio M. Ferreira Moreira

Regional Quality Engineer KAEA | Project Management | Quality Management | VDA 6.3 Certified | VDA FMEA & Reverse FMEA | Master’s in Chemical Engineering | Process Optimization | Data Analysis |
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After identifying a timeline to collect your data, repeat that process a few more times. However, this time choose a timeline where everything worked OK according to your quality standards. This way, you will easily identify and visualize trends and It will be much easier to notice where things went wrong by comparison.

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4 Implement Solutions

With a probable cause in hand, you can begin implementing solutions. This may involve adjusting machine settings, revising work procedures, or upgrading equipment. It's essential to apply changes methodically and monitor their impact. If the first solution doesn't fully resolve the problem, use the feedback to refine your approach. Remember, effective troubleshooting is iterative, and solutions should be continuously improved upon.

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Fábio M. Ferreira Moreira

Regional Quality Engineer KAEA | Project Management | Quality Management | VDA 6.3 Certified | VDA FMEA & Reverse FMEA | Master’s in Chemical Engineering | Process Optimization | Data Analysis |
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Define concrete actions with reasonable due dates. At this point, monitor everything using a PDCA cycle to track the progress and effectiveness of your actions. (100% it's only when you test your solution multiple times and not when you implement it.)

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5 Monitor Results

After implementing solutions, closely monitor the results to ensure that the problem has been resolved. This monitoring should include the same metrics and observations used in the initial stages to identify issues. If the problem persists or new issues arise, you may need to revisit your analysis and consider alternative solutions. Continuous monitoring is key to maintaining control over manufacturing processes and preventing future problems.

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6 Refine Processes

Finally, use your troubleshooting experience to refine your manufacturing processes. This could mean updating standard operating procedures , providing additional training to staff, or implementing new quality control measures . Continuous improvement is a hallmark of successful manufacturing operations, and each problem you solve contributes to building a more robust and efficient system. Remember, troubleshooting is not just about fixing problems; it's about enhancing your entire manufacturing process.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Gerry Lo

Retired
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Root Cause Analysis and Failure Mode Effects Analysis are well known methodologies. Practical and pragmatic application needn’t entail very much time or effort A product launch was delayed when the regulatory agency expressed concern over the key excipient. The supplier and agency’s own website showed it has been successfully used for decades The same product suddenly failed rheological testing. Simply asking the team whether the instructions all were followed revealed that the requisite vacuum degassing step had been neglected A troubleshooter was baffled when, after a coil aseptic heat exchanger was subjected to freezing, flow was restricted. The OEM explained internal baffles had deformed

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Here's how you can analyze and troubleshoot problems in manufacturing.

1

2

3

4

5

6

7

1 Identify Issues

2 Gather Data

3 Analyze Patterns

4 Implement Solutions

5 Monitor Results

6 Refine Processes

7 Here’s what else to consider

Manufacturing

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Here's how you can analyze and troubleshoot problems in manufacturing.

1

2

3

4

5

6

7

1 Identify Issues

2 Gather Data

3 Analyze Patterns

4 Implement Solutions

5 Monitor Results

6 Refine Processes

7 Here’s what else to consider

Manufacturing

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