| 5 ME |
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. |
| 80-20 rule |
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. |
| analytical data |
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. |
| blister |
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. |
| brainstorming |
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. |
| breakpoint |
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. |
| cause and effect diagram |
A fishbone diagram. A graphical tool used to identify and isolate potential causes of any defect. |
| check sheet |
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. |
| defect |
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. |
| deviation |
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. |
| downtime |
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. |
| environment |
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. |
| fishbone diagram |
A cause and effect diagram. A graphical tool used to identify and isolate potential causes of any defect. |
| hypothesis |
A tentative guess that is based on observation and that can be tested through further observation and research. |
| initial name syndrome |
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. |
| inspection |
The examination of a part to determine if it meets specifications. Coating inspection can occur during or after coating application. |
| machine |
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. |
| man |
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. |
| material |
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. |
| measurement |
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. |
| method |
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. |
| optical inspection |
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. |
| Pareto chart |
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. |
| predictive maintenance |
A maintenance approach that involves testing and monitoring machines in order to predict machine failures. |
| problem |
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. |
| problem statement |
A description of the issues that need to be addressed. Defining a coating defect enables the formation of a problem statement. |
| process control |
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. |
| process information |
Data regarding each process used to prepare and make a part. Both qualitative data and quantitative data are collected when gathering process information. |
| production run |
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. |
| qualitative data |
Descriptive information about a part or process. Qualitative data is subjective information that usually is not measured. |
| quantitative data |
Information that is measured and recorded. Quantitative data is objective information and is usually a number. |
| real time inspection |
An inspection technique that involves examining a coating during each stage of its process, from surface pretreatment through application and curing. |
| root cause |
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. |
| standard operating conditions |
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. |
| standard operating procedure |
A document describing an organization's model processes. It contains a moderate amount of detail about the techniques and equipment used in the process. |
| troubleshooting |
A systematic approach to solving problems quickly and efficiently. Troubleshooting focuses on identifying the root cause of a problem and fixing that cause. |
| visual inspection |
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. |