How to Managing Production Anomalies in Prototype Workshops
Ever wonder how we at Creatingway manage prototype production anomalies or errors. Here are a few practical tips our experts follow to prevent them. It depicts how we manage production anomalies in our prototype workshops.
Product anomaly management refers to a set of measures and protocols we use to:
- Detect errors and emergencies
- Control errors and emergencies
- Solve errors and emergencies
It mainly serves regular orders, low volume production, and those with short turn-around. Moreover, cases of production anomaly may appear when
- Buying of material
- CNC prototyping
- Quality control
- Production delay
Most production anomalies later have a knock-on effect. Ultimately, it may affect client approval. Therefore, it is vital to have spot-to-spot check-ups. This allows one to respond to production anomalies quickly. Moreover, it helps avoid relapse.
Key Steps to Manage Production Anomalies
We follow five major steps to regulate prototype production anomalies. These steps allow us to minimize their occurrence rate. Below is further insight into this.
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Preparation
Typically, we define the production anomaly using the involved step in our prototype workshops. It may fall under the buying of raw material, CNC programming, CNC machining, sanding, or polishing. We then create rules that determine how we handle such anomalies. For instance, it may come in the form of a Corrective and Preventive Action Report.
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Finding the Anomaly
By first spotting the anomaly, we can proceed to report its status. A status report may contain the process, extent, and quantities. After that, the experts in charge will confirm the anomaly and direct the necessary response.
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Actions
We first assess the loss and degree of the anomaly. Afterward, we can come up with the needed solution. Moreover, we can coordinate with the involved departments to resolve the issue quickly.
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Tracing Causes and Following Up
We first proceed to find out the possible causes. We can then proceed to take up measures to manage production anomalies. This may help us avoid any future relapse of the same. After that, we monitor the viability of the measures for long-term use.
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Holding a Precaution Meeting
After solving an anomaly, we proceed to teach our workers how to detect and correct them.
Types of Production Anomalies and Cases at Prototype Workshops
Identifying production anomaly is helpful in managing them.
Material Anomalies
Most prototype workshops take up an array of orders that need different materials. As a result, we may not stock up all the needed raw materials. A viable choice is to buy them after every order. In this case, we only buy materials from shops that stock up all sorts of materials. This ensures proper quality control. Buying the material is the first step of production. Therefore, failing to detect material anomalies early, you end up with a low-quality prototype.
A Creatingway we are able to detect and manage material production anomalies early. Moreover, we at times do not need expert tools and can detect the errors using basic parameters. Examples of these parameters are hardness and density. The material composition of finished prototypes may lack certain specifications.
Case Study
At our prototype workshops. Sometimes, we use polyethylene when producing prototypes. It comes in several sub-forms that differ in terms of features. We make marine prototypes using PE1000. It has a lower density than water and thus floats on it. One common product anomaly is the addition of glass fiber. This combination is denser than water and results in sinking. In addition, we happen to identify and manage this anomaly by first putting the prototype in water.
CNC Machining Anomalies
Most prototype shops lack the capacity to design. Thus, they stick to the given CAD drawings, 2D drawings, and 3D data when designing. CNC programming directs how the machine will process the material. Luckily, our team of experts is up to the task. We first code for the needed structure. After that, we proceed to design the tooling routine to attain an effective machining process.
A few common CNC anomalies are namely:
- Ignoring the microfeature
- Over cutting
- Undercutting
Case Study
Take the case of a CNC machined tube that has a few lug bosses 0.5mm high. The original machining step for sealing the ring first involves sealing the ring to the dotted line on the lathe. This is often 0.5mm higher than the required ring width. We then proceed to mill the lug bosses on a 3-axis CNC machine. However, this may not be possible due to the over-cutting 0.5mm height material.
Post Finishing Anomalies
A few common finishing processes at our prototype workshops as below. In addition, we also are able to make more surface finishing processes based on customers’ specifications such as mirror polishing.
- Sanding and polishing
- Anodizing
- Electroplating
- Powder coating
- Laser etching
- Chroming
In conclusion, we perform a few of our in-house finishes via handcraft. Our experts enable us to achieve top-notch finishes through their delicate approach. Inexperienced prototype producers may find it tasking to regulate their handcraft. Most importantly, variations arise between companies despite the use of similar tools. Common post finishing prototype anomalies are namely.
- Mismatch in color when powder coating
- Uneven chroming or anodizing
- Attached stains
Creatingway is concentrated on CNC machining manufacturing, prototype machining, low-volume manufacturing, metal fabrication, and parts finishing services, provide you the best support and services. ask us one inquire now.
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