在高卷中运行更高空化模具的商店将永远不会在评论领域中使用非标准语言不断提高模具性能或商店效率。该数据收集方法不提供快速或准确地测量数据的方法,因为技术人员必须手动解密和分析每个工作单。迁移到更具数据驱动,4.0或科学类型的维护文化避免了这种类型的体力劳动。

we have to review the various maintenance cultures found within shops, identified necessary mold data and explained the inadequacies of journal-entry systems. Now, let’s discuss the type of data that a shop must collect and the most appropriate means of data collection.

普遍维护目标

Maintenance and repair data aim to help provide molds and technicians with the best opportunity “to efficiently produce quality parts on time.” Although maintenance data can be of great value to those upstream and downstream of maintenance and repair, the specific data type needed to better design, manufacture and run (process) a mold will vary.

维护和维修数据必须专注于防止模具有效,可靠地运行特定数量的可接受的部件(规格),以可接受的风险等级。实现这一目标(工具,劳动,外部工作,运输模具等)的成本控制了我们目标的效率方面。

Categorization of Required Data

商店需要收集各种维护数据类型。这些类别基于模具的运行/修复周期。在收集和使用数据进行故障排除的数据时,运行/修复周期中的“事件序列”对于适当的根本原因分析,可能是至关重要的。在模具中收集的数据被称为生产运行数据,包括按号,启动和停止日期和时间,循环计数,启动处理器的名称和模具停止原因。来自压力机,循环计数器或过程监控系统的电子信号可以捕获这些数据点中的一些。

在没有生产运行数据的情况下无法创建智能,准确的维护计划。想想它 - 如果自上次改变以来,你会在不知道它是多少里程的情况下更换汽车中的油?当然不是,因为它取决于谁在驾驶汽车,在汽车被驱动的环境中(光滑的公路或坑砾石路),是汽车是否沿途崩溃,如果是的话,英里的数量它在崩溃之前跑了,击穿的原因和所需的纠正措施将其返回到可驱动状态,以命名为一些。

请问事实

模子ers are always surprised what they learn about their molds when this production run data is presented to them in a report based over time. Ask any manager what mold is costing them the most in unscheduled stops or tooling components, or which mold has the highest number of labor hours or quality issues, and most managers will point to the mold on the bench that day. Toolroom managers and repair technicians working in a firefighting environment rely on their experience with daily issues to know what molds are causing the most issues and what corrective actions were taken. However, real data surprises most toolroom personnel, mostly because there is no emotional attachment to the hot issue of the day—only facts. The facts allow toolrooms to set targets and goals because facts are based only on numbers.

缺陷跟踪数据

缺陷信息是下一步,是非标准语言可以在无用的情况下进行跟踪和故障排除。修复技术人员,工艺技术人员,质量控制甚至工程之间的不同名称可以了解单一缺陷。所有成型缺陷必须具有标准化的名称/术语,因此每个人都可以理解和跟踪它们。

多年来,与数百家公司合作揭示了部分质量问题的严重缺乏标准化。单靠闪光灯,刻录或非填充等笔记是不充分的描述,以确保模具遭受诸如刷新的闪光和/或哪些模具组件正在创建问题。

Standardize your terms to include the defect’s location such as “flash on seal,” “burn on tab,” or “long gate.” Do not say “flash on the top of the seal by the valve.” Be mindful that this is a term—not a sentence.

Keep the term as short as possible (two or three words). Some molders have hundreds of different defects across hundreds of molds, and it is critical to be specific for targeting the high-frequency issues.

Other documentation systems use coded defects—like “FLSS”—which would be code for the previously mentioned defect. Coded defects can be confusing to decipher and time-consuming for the user to ensure is correct. It is better to keep it simple to ensure accuracy.

Defect data also include the defect type. Although there could be several different categories of issues, there are five primary types: electrical, mold, part, process, or maintenance. This makes it easier to run reports to categorize issues and expand the list of goals. Additional defect categories should relate to the type of products and molds your shop maintains.

The exact date the defect was noticed, the person who noticed the defect, and if relevant, the mold position or cavity number of the defect are other essential data points. Without this positional data, trends and patterns related to improper cooling, incorrect tooling stack dimensions, unbalanced mold fill, tooling configurations, unnoticed non-uniform manifold heat profiles, or corrective actions will be applied as short-term successes that only mask the root cause.

Corrective Action Tracking

在大多数系统中使用令人困惑的是,当可以在纠正措施“术语”上的所有纠正措施时,在大多数系统中使用“故事”。

例如,诸如“更换”的“清洁”,“重新工作”和“抛光”提供了一种方法来提供一种测量频率并将直接成本与模具和商店中的工作类型相关的手段。有时,需要说明以更好地解释一个过程,但是需要使用术语来收集任何有用的数据。您还可以直接将术语与缺陷联系起来,以确定该分辨率如何有效。

纠正措施术语还允许技术人员对新或更好的设备进行标准,例如超声波或干冰清洁,TIG或激光焊机,抛光设备或更好的手动工具。

Love for Accurate Maintenance Records

The great thing about accurate, measurable maintenance records is that everyone is associated directly with mold performance benefits, from repair technicians to mold designers to managers. When a system is designed to be granular enough to benefit maintenance, then everything else summarizes that data—or reports.

例如,设计人员和建造者可以通过执行供应商引脚,衬套,互锁和其他框架组件的头部到头分析来看最佳的现成的成本。他们还可以更好地分析设计特征,如冷却方法,电镀,钢型,热流道系统或电气元件是否改进。

提高数据准确性的常见障碍是需要系统化的维护实践,这必须基于公司文化或文档“技能”水平来开发,以实现短期和长期目标。系统的过程将不仅仅是要求修理技术人员“写下你所做的事情”。

Explain the Goals and Teach the Process

搬到更具成本效益和更安全的文化比继续管理日常消防更好。尽管如此,一旦开发维护过程,它必须变成强制性工作。这可能是一个艰难的卖出,经验丰富的技术人员习惯于在模具在他的长凳上落地时,所以要了解这种维护系统的实施需要适当的期望和福利培训;否则,新系统注定要失败。