Machine Malfunction & Operator Errors

Hybrid said:

For example Operator Error: Operator did not do periodic visual inspection

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Your example shows a bias. The operator missing inspection was not the original cause of the defect. It seems there was something wrong with the part or way the parts in the assembly went together, whether the operator was looking or not.

Steve Prevette said:

At a Navy torpedo facility where I worked many years ago - a Pareto chart came out that said that the sailors doing the maintenance were the number one cause of torpedo failures found during test firings. Caused quite a stink shall we say. Careful review of the data showed that all "sailor errors" were lumped into one bin, but equipment failures were individual to the component. So we had six sailor failures, one engine failure, one CPU failure, one . . . failure - the list was a long one. Plus many of the sailor failures were related to poor procedures supplied to the facility.

Not a bad idea to have more detail for ANY failure. The responses above should help you. Blaming the operator(s) usually is a red herring - there is something behind those failures. Consider Dr. Deming's Red Beads.

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Mark 48?

Ed Panek said:

Mark 48?

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Mk 48 ADCAP, when it was new in the early 1990's.

Steve Prevette said:

Mk 48 ADCAP, when it was new in the early 1990's.

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I served on USS Whipple FF 1062 Knox Class from 87-91. Not sure what we used at that time.

Following Steve's lead...rarely is the root cause "operator error..." from Dr Deming; loosely quoted - " a bad system will beat a good employee everytime.."

Hybrid said:

Made a list to capture any parts we reject. One section i put "Machine Malfunction/Operator error".

Upon presenting my list to supervisors they asked me to put into more detail for both of them.

Any idea on what i can detail them each into? I need examples of machine malfunctions and operator errors

For example Operator Error: Operator did not do periodic visual inspection.



Can anyone throw any ideas at me?

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Here are some examples of machine malfunctions and operator errors that you can include in your list:

Machine Malfunctions:

Power failure: Sudden loss of electricity supply to the machine, resulting in its shutdown and inability to operate.
Mechanical breakdown: Failure of a specific component or part, such as a motor, gearbox, or sensor, leading to the machine's inability to function as intended.
Sensor malfunction: Incorrect readings or failure of sensors, which can cause the machine to operate inappropriately or produce faulty results.
Software glitch: Errors or bugs in the machine's software programming, leading to unexpected behavior or system crashes.
Conveyor belt jam: The conveyor belt getting stuck due to material accumulation, causing a halt in the production process.
Cooling system failure: Inadequate cooling or failure of cooling mechanisms, resulting in overheating and subsequent machine malfunction.
Operator Errors:

Improper calibration: Incorrectly setting the machine's parameters or failing to calibrate it regularly, leading to inaccurate outputs or faulty operation.
Inadequate maintenance: Neglecting routine maintenance tasks, such as lubrication or cleaning, which can contribute to premature wear and tear or malfunction of machine components.
Incorrect material loading: Loading the wrong type or quantity of materials into the machine, causing operational issues or damage to the equipment.
Failure to follow operating procedures: Deviating from established protocols, bypassing safety mechanisms, or skipping essential steps during operation, leading to errors or accidents.
Lack of training: Insufficient knowledge or training of the operator, resulting in incorrect handling of the machine or misinterpretation of instructions.
Negligence in safety protocols: Failing to follow safety guidelines, such as wearing appropriate protective gear or not properly securing workpieces, leading to accidents or damage to the machine.

And how is person recording the defect supposed to know this? While well intended I think your post misses the point: Read my previous response and think about what we are really trying do to here…

Hybrid said:

Made a list to capture any parts we reject. One section i put "Machine Malfunction/Operator error".

Upon presenting my list to supervisors they asked me to put into more detail for both of them.

Any idea on what i can detail them each into? I need examples of machine malfunctions and operator errors

For example Operator Error: Operator did not do periodic visual inspection.



Can anyone throw any ideas at me?

Click to expand...

Do you collect the data yourself or you just pass by and put the data from the machine operator to your own excel sheet? If you look at data to start investigation and improve process , first MAKE sure the data collection is correct. Operators have targets and do not waste much time, often they just choose one defect and register most of the scrap as a single defect or two maybe. For instance - short short or flash whereas the actual situation is very different and the defects are different. With such incorrect data you cannot do anything.

For the rest of the process the approach from Bev D is the best one. Go to GEMBA and observe yourself the actual process and the actual defects. You should dedicate your time and leave other work behind in order to observe the actual process as much as it is needed and improve it by eliminating the root-causes, not the symptoms which is often done instead. Robust root-cause analysis takes a lot of time and dedication.

Once you have sufficient data focus on top defects and start working there, elimination of 1-2 top defect per week will improve KPI's in the long-term significantly.