Fault recording and analysis of injection molding machines: key steps to prevent recurrence of problems
Injection molding machine as an indispensable equipment in modern manufacturing industry, its stable operation has a direct impact on production efficiency and product quality. However, machine failure is inevitable, and how to record and analyze these failures effectively to prevent their repetition has become the focus of maintenance work. We will explore how to record, analyze and prevent the common faults of injection molding machines through scientific and rigorous methods to improve the stability of production lines and the economic benefits of enterprises.
First of all, accurately recording faults is the basis for analyzing and solving problems.
Whenever the injection molding machine fails, the operator or service technician should immediately record the following information in detail: the time of the failure, the model and serial number of the machine, the symptom of the failure, the possible cause of the failure, the temporary measures taken and the final solution. This data needs to be systematically collated and stored for future queries and analysis.
Secondly, logical analysis of failure causes is crucial.
Once the failure is documented, an in-depth analysis is required to determine the root cause. This usually involves a thorough review of the machine’s usage history, operating conditions, maintenance records, and the specific environment in which the failure occurred. Using analytical tools such as 5 Whys and fishbone charts can help the team trace back to the source of the problem.
Furthermore, rigor is equally important in fault analysis.
This means using technical terms to correctly describe failure situations and ensuring that all assumptions are based on facts and figures. For uncertain information, it should be clearly marked and verified in subsequent studies or experiments.
Easy to understand communication is also essential for cross-functional collaboration. Operators, service technicians, engineers, and managers should all be able to understand the results of fault logging and analysis so they can collectively take action to prevent failures from happening again. For example, if a component is found to fail frequently, it can describe its failure mode in easy-to-understand language and propose specific improvement measures, such as strengthening regular inspections of the part or changing suppliers in advance.
The transmission of positive energy also plays an active role in the improvement process. Maintaining a positive attitude in the face of failures and encouraging team members to come up with innovative solutions can motivate employees, promote knowledge sharing and team cooperation.
Case study
For example, an injection molding machine repeatedly has the problem of unstable injection pressure. Through recording and analysis, it was found that it was caused by the wear of a valve in the hydraulic system. The team decided to make design improvements to the valve and added special maintenance instructions for this valve to the operating manual. As a result, the problem of pressure instability was not only solved, but also the stability of the entire production line was enhanced by the spread of improvement measures.
Conclusion
Through scientific and rigorous recording and analysis of injection molding machine faults, not only can problems be found and solved in time, but also can prevent similar faults that may occur in the future. This approach requires not only accurate data collection, a logical analysis process, and easy to understand information transfer, but also continuous positive energy and positive improvement of the corporate culture. Only in this way can we ensure the efficient and stable operation of the injection molding machine, and then guarantee the production quality and enterprise efficiency.
