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5 ME
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A term used to describe the six main causes of problems: man, method, machine, material, measurement, and environment. 5 ME is often used to organize the parts of a fishbone diagram.
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80-20 rule
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A principle stating that, in general, 80% of problems arise from 20% of causes. Pareto charts are often used to demonstrate the 80-20 rule.
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analytical data
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Information obtained by breaking down a coating process into its individual parts and comparing these parts to the finished coating. Analytical data is gathered by physically examining each aspect of a process.
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blister
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A small, dome-like bulge in the coating film or a small recess in a coating film. Typically blisters are caused by trapped moisture, rapid drying, and the use of improper solvents.
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brainstorming
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An activity in which an individual or group rapidly lists ideas, problems, or solutions. Brainstorming can be used in the troubleshooting process to identify possible problem causes or to form hypotheses.
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breakpoint
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The point at which the slope of the line on a Pareto chart becomes much less steep. This point incates that the problems to the right of the point are much less frequent than those on the left.
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cause and effect diagram
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A fishbone diagram. A graphical tool used to identify and isolate potential causes of any defect.
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check sheet
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A visual tool for tracking data and making decisions by placing tic marks into different cells to create a graphical representation of the data being tracked.
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defect
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An irregularity in the specified and expected finish of a part. Typically, a coating defect either negatively impacts a coating's aesthetic appeal or impairs a coating's functionality.
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deviation
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A situation that is less than ideal but is temporarily acceptable. A coating with bubbles that do not affect its quality or performance is an example of a deviation.
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downtime
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Unproductive blocks of time during which machine operations cease, often due to mechanical problems. Downtime raises a company’s financial costs, which leads to financial losses.
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environment
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In 5 ME, the factor that represents the potential for error due to the surrounding area in which the process occurs. This and other factors in 5 ME are often organized in a fishbone diagram.
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fishbone diagram
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A cause and effect diagram. A graphical tool used to identify and isolate potential causes of any defect.
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hypothesis
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A tentative guess that is based on observation and that can be tested through further observation and research.
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initial name syndrome
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The process of addressing an indirect cause and consequently taking an inappropriate course of action to remedy a defect resulting from incorrectly naming the defect. Initial name syndrome often occurs when a particular defect is named before being properly defined.
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inspection
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The examination of a part to determine if it meets specifications. Coating inspection can occur during or after coating application.
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machine
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In 5 ME, the factor that represents the potential for error due to equipment performance. This and other factors in 5 ME are often organized in a fishbone diagram.
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man
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In 5 ME, the factor that represents the potential for human error. This and other factors in 5 ME are often organized in a fishbone diagram.
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material
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In 5 ME, the factor that represents the potential for error due to quality problems with stock or other items used in a process. This and other factors in 5 ME are often organized in a fishbone diagram.
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measurement
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In 5 ME, the factor that represents the potential for error due to problems with certain instruments. This and other factors in 5 ME are often organized in a fishbone diagram.
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method
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In 5 ME, the factor that represents the potential for error due to incorrect or outdated instructions and practices. This and other factors in 5 ME are often organized in a fishbone diagram.
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optical inspection
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A method of inspection that uses sight, light, and magnification to inspect the features of a part. Automated optical inspection machines reduce the chances of human error.
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Pareto chart
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A visual tool used to identify the causes of problems that occur most frequently. Pareto charts are often used to demonstrate the 80-20 rule.
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predictive maintenance
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A maintenance approach that involves testing and monitoring machines in order to predict machine failures.
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problem
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A situation that is unacceptable and must be corrected, in many cases as soon as possible. A coating that does not meet quality demands is an example of a problem.
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problem statement
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A description of the issues that need to be addressed. Defining a coating defect enables the formation of a problem statement.
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process control
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A method of checking product performance and batch consistency by regularly measuring and regulating processes that yield a product. Coating companies often seek to prevent coating defects through effective process control systems.
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process information
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Data regarding each process used to prepare and make a part. Both qualitative data and quantitative data are collected when gathering process information.
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production run
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The collective processes that are necessary to manufacture a group of similar or related parts. During troubleshooting, trial production runs are performed to test solutions.
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qualitative data
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Descriptive information about a part or process. Qualitative data is subjective information that usually is not measured.
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quantitative data
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Information that is measured and recorded. Quantitative data is objective information and is usually a number.
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real time inspection
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An inspection technique that involves examining a coating during each stage of its process, from surface pretreatment through application and curing.
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root cause
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The true origin of a problem as opposed to the symptom of a prior cause. Troubleshooting focuses on identifying the root cause of a problem rather than simply addressing the symptoms.
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standard operating conditions
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The environment in which production runs normally occur. Trial production runs must be performed under standard operating conditions to test solutions to problems in a process.
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standard operating procedure
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A document describing an organization's model processes. It contains a moderate amount of detail about the techniques and equipment used in the process.
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troubleshooting
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A systematic approach to solving problems quickly and efficiently. Troubleshooting focuses on identifying the root cause of a problem and fixing that cause.
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visual inspection
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A routine stage of a finishing operation that involves closely examining a part with the naked eye immediately following its production to check for defects.
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