Page 26 - Injection Molding Advanced Troubleshooting Guide

1.4 Troubleshooting Methodology 7

1.4.3„ STOP: Observe

Observation is critical to solving problems. Much like Sherlock Holmes, a good
molding troubleshooter must observe as much as they can regarding the problem
and environment.
Observation should be a multiple sense process, meaning look, listen, and even
smell what is happening at the molding machine. Visual examination of the parts,
the equipment, and the process will most often provide valuable clues. However,
when observing a molding machine in operation, the smell of degraded plastic
may be an overwhelming indicator of a problem. Strange noises can also be an
indication of something wrong in the process. Always observe with all senses to
try to discover any clues to the cause.
When observing a molding process, a walk around the machine is usually a good
practice. A quick walk can often highlight a concern that must be addressed. Key
things to look for include:
ƒ Auxiliary setpoints and actual values
ƒ Hot runner controllers
ƒ Thermolator
ƒ Chiller
ƒ Dryer
ƒ Gas assist equipment
ƒ Clamp and robot movements
ƒ Trimming operations
ƒ Operator handling
ƒ Material identified and correct
ƒ Clear standards available?
ƒ Anything that is damaged or out of place
Figure 1.1 shows a simple chart called the 4M Basic 8. These are the basic items
that need to be observed during initial troubleshooting. Many problems can be
resolved by simply working through these eight questions, and a “no” answer for
any of these questions indicates a likely starting point for resolving the problem.
The 4M Basic 8 is a very simple procedure that all molders should be able to work
through and answer prior to calling for technical support. Utilizing the 4M Basic 8
or something similar as a starting point for troubleshooting puts good habits in
place for troubleshooters.