Re: Fixing errors
Quote
"Another policy was to tell the operators that, if they made a mistake, to talk about it and they would not get in to trouble."
This is the line I use all the time on our operators, own up, confess to have borked things, then we can either give you a bit more/different training or re-write the programs to prevent you(or anyone else) from making the same borkage.
Had one machine smash a 6 inch tool straight into the job when the operator hit start... needless to say this was very loud and everyone went to brown alert.
On finally persuding said operator to confess , it turned out that he'd slammed the safety door shut faster than he should have done, the PLC picked up the the door as being shut and allowed start to be pressed, which then commanded the door lock to come in and lock the door.... however the lock bolt could not engage, and so the machine threw an error "door not locked".
Operator then shut the door properly and hit start.
Everything locked, but the machine had a read ahead buffer of 5 lines, so when it hit the first error , it dumped the buffer, on the 2nd start it started from 5 lines in.... and missed out a vital setup command... hence the crash. (this fault diagnoses took me the better part of 1/2 a day)
So procedure and training were changed than on a door not locked alarm, the operator(s) were to find a setter and get them to reset the machine. and no more crashes.
plus the operators were far more open about borkages as they saw that they would not be fired for causing a major borkage.(unless they did the same thing 3 times in a row and got told to leave the building via the wood chipper....)