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What do you do if you're facing technical glitches with new manufacturing technology?

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Adopting new manufacturing technology can be a game-changer for your production efficiency and product quality. However, it's not uncommon to encounter technical glitches during the initial phase of implementation. These hitches can range from software bugs to hardware malfunctions, often leading to downtime or suboptimal performance. Knowing how to navigate these challenges is crucial to minimizing disruptions and leveraging the full potential of your investment in cutting-edge manufacturing systems.

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Mitchell Hammontree

Technical Service Technician at Smiths Detection
Yogesh Sanjay Rai

Project Manager at SULZER | Ex-EagleBurgmann | Ex-Ultra Corpotech
Mike Spencer

Mechanical engineer working in the entertainment industry.

1 Assess Quickly

When a technical glitch arises, your first move should be a swift assessment. Pinpoint the issue's nature, scope, and impact on production. Is it a software error or a hardware failure? How is it affecting the workflow? Understanding the problem's dimensions will help you gauge the severity and decide whether it's something you can troubleshoot in-house or if you need external support. Time is of the essence in manufacturing, so a quick yet thorough evaluation is key to getting back on track.

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Yogesh Sanjay Rai

Project Manager at SULZER | Ex-EagleBurgmann | Ex-Ultra Corpotech
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The first thing is to understand the glitch and come to a position where the machine/process can be started on the go in safe mode. For this a thorough understanding of the process/workflow comes handy. Next is to determine if this is something that's standalone or has a propensity to repeat itself, in which case the PFMEA needs to be drawn and revalidated. Next is to find an alternative to the affected articles/people/workspace on the line, this requires thorough investigation and final call from the QA/resources team

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2 Consult Manuals

Once you've identified the problem, consult the operation manuals and technical documentation that came with your technology. These resources are designed to provide guidance on common issues and their resolutions. Look for troubleshooting sections or FAQs that might address your specific problem. Manufacturers often include detailed steps to resolve known issues, which can save you valuable time and effort in getting your systems back online.

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Yogesh Sanjay Rai

Project Manager at SULZER | Ex-EagleBurgmann | Ex-Ultra Corpotech
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Consulting manuals is a good way to begin, but problems may be benign and not thoroughly envisaged in the process, under such situations experience of people in the process and on the job is the most potent decision helper.

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3 Contact Support

If the manuals don't resolve the issue, reach out to the manufacturer's customer support or technical assistance team. They have the expertise and experience to help you navigate complex glitches. Be prepared to provide detailed information about the problem, any error messages, and the steps you've already taken. This will allow the support team to offer more targeted assistance, and they may be able to remotely diagnose or even fix the issue.

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4 Engage Experts

Sometimes, glitches are too complex for quick fixes and require professional intervention. In such cases, consider engaging a technical expert or a service engineer who specializes in your particular technology. An expert's insight can be invaluable, and they can often identify and resolve issues that are not immediately obvious. They might also provide training or tips to prevent similar problems in the future.

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Mitchell Hammontree

Technical Service Technician at Smiths Detection
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Drive down into the system to verify if it is electrical, mechanical, or software related. Often times you will find that it is something simple, other times it is a combination of errors. The devil is in the details a wise man once told me. I find this to be so true. Double check before your work, physically follow the path of the issue. Sometimes it takes going to a different task to have an epiphany and you fix it by something that was buried deep in your mind that you were blocked from remembering because of frustration. Take a breath, walk away. It will be there tomorrow. MH

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Mike Spencer

Mechanical engineer working in the entertainment industry.
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Definitely a good idea when you feel out of your depth with new machinery. Complacency isn’t equal to competency and many companies and individuals don’t recognise that! If you are struggling with new tech or you have a problem where you feel all options within your competency have been exhausted, always reach out to the manufacturer and their experts!

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5 Update Regularly

To prevent future glitches, ensure that your manufacturing technology is always running the latest software updates and patches. Manufacturers frequently release updates that fix known bugs and improve system stability. By keeping your systems up-to-date, you reduce the risk of encountering preventable glitches that could have been resolved with the latest software version.

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6 Document Everything

Finally, document every glitch and the steps taken to resolve it. This record-keeping is essential for several reasons. It helps you track recurring issues, provides valuable feedback to the manufacturer for future improvements, and serves as a knowledge base for your team. By maintaining detailed logs, you can expedite troubleshooting in the future and potentially prevent downtime by recognizing patterns that lead to glitches.

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Yogesh Sanjay Rai

Project Manager at SULZER | Ex-EagleBurgmann | Ex-Ultra Corpotech
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Documentation needs to be solid and updated with all intricate details in order to help the future reference, secondly PFMEA is to be rock solid too. One machine can play different levels of importance in different processes and hence for the workflow/processflow what importance does it play depends on the organisation and the process. Hence, this needs to be taken with absolute care to troubleshoot and avoid future problems

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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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What do you do if you're facing technical glitches with new manufacturing technology?

1

2

3

4

5

6

7

1 Assess Quickly

2 Consult Manuals

3 Contact Support

4 Engage Experts

5 Update Regularly

6 Document Everything

7 Here’s what else to consider

Manufacturing

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What do you do if you're facing technical glitches with new manufacturing technology?

1

2

3

4

5

6

7

1 Assess Quickly

2 Consult Manuals

3 Contact Support

4 Engage Experts

5 Update Regularly

6 Document Everything

7 Here’s what else to consider

Manufacturing

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