Troubleshooting Process Problems

Often troubleshooting guides are provided by equipment manufacturers for common problems. These guides are helpful for many of the simpler problems associated with the equipment. Some resin manufacturers are an excellent resource for troubleshooting processing problems that are specific to a resin. Subject matter experts or extrusion consultants are also resources for troubleshooting an extrusion process. 

These examples are used for illustration purposes only, and we do not mean to imply that the explanations given will always fit scenarios you will see in your own processes. Certainly, as stated earlier, process changes could have resulted ill the time plots shown. However, the point we wish to make emphatically is that sampling should be on any checklist for troubleshooting process problems and should be taken seriously as a possible cause for problems. 

Data collection, organization, and analysis are another approach that can be used to troubleshoot process problems. Check-sheets are used to collect large quantities of data. This quantitative data can be organized into graphics or trends to plot process variation or changes. Data analysis utilizes a variety of quality techniques to put all of the parts in place. Control charts are frequently used to assist process technicians in operating a complicated process. Quality tools include a variety of methods designed to improve product quality. 

Describe the varied instrumentation used to troubleshoot process problems. Distinguish between primary and secondary problems. 

Today polymers scientists rely on many different methods of instrumental analysis to develop, test, and classify macromolecules. Infrared (IR) spectroscopy, one of the most important analytical tools in research as well as in manufacturing, is used to test the quality of incoming monomers, to control processes, to control quality control, and to confirm quality of intermediates and final products. IR is even used to troubleshoot processing problems and to analyze the competitor s products. IR spectroscopy has value in structure elucidation and quantitative analysis of polymers. Hausdorff [6] and Kagarese and Weinberger [7] were the first to publish collections of IR spectra of polymers. 

Thermal analysis (TA) consists of a family of analytical techniques in which a property of the sample is monitored against time or temperature while the temperature of the sample is programmed. The properties include weight, dimension, energy take-up, differential temperature, dielectric constant, mechanical modulus, evolved gases, and other, less common attributes. The application of thermal analysis is widespread within the polymer and elastomer industries. Thermal analyzers are used to qualify a material for fitness of use and to troubleshoot processing problems. Thermal analysis consists of three primary techniques that may be used individually or in combination ... 

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