Follow the Root Cause Analysis principles and use it as a starting point to be proactive. Like a PFMEA, just makes it more visual.

1. INTRODUCTION Quality Instruction
Error Proofing - Proactive NOT Reactive
MAN (PEOPLE)
Give purpose to employees
Build a winning Team
Make them feel they belong (uniforms?)
Guidance (write procedures)
Training (Teach the procedures)
Discipline (Enforce the procedures)
Ideal Work Environment (Temp Control)
METHOD (PROCESS)
Organized (Number and Color scheme)
Process Flow (Smooth / More steps = more errors)
Standardized Work (Clear and easy to follow)
Measure Progress
Ideal Environment (Clean - Include in tasks)
Cycle of Improving (Kaizen) put in to standards
JHA / PPE & Ergonomics Assessment (Prevention)
ENVIRONMENT (UNCONTROLLABLE)
Implement Controls (Temperature and Humidity)
Create Parameters by weather changes
Sensors and Alarms added to detect temp & RH limits reached
Work with suppliers to fine-tune material use limits (extend shelf life)
Seasonal Planning
Primary Cause
LOOPHOLE : Basically, where you
missed in planning (PFMEA) and
now have to trace back.
BREAKDOWN
(Problem> Issue> Opportunity)
ISHIKAWAISHIKAWAISHIKAWAISHIKAWA
DIAGRAMDIAGRAMDIAGRAMDIAGRAM
MATERIAL
Create Receiving Inspections (use sample images)
Train on the Inspections
Hold suppliers to higher standard / Accountable
Audit Suppliers
Develop special products for your application (tweak
formula)
Standardize specifications of what you accept
MACHINE (EQUIPMENT)
Fine-tune Parameters
Well written Start-Up procedures (operator inspections)
Well written PMs (adjusted to meet production)
Well Scheduled PMs
Easy to follow Spec Sheets
Calibrations current
PROJECT TEAM
(Never do alone / More perspectives = Less missed)
PM - Project Manager
S - Safety & Environmental
E - Engineering
QC - Quality Control
P - Production
T - Transportation
F - Planning (forecasting)
O - Open for new participant
P
PM
S QC
T
F
E
O
DESIGN (PLANNING)
Develop revision process / Document control
Create feedback / suggestions program
Periodic review of industry trends
Test products to point of failure and adjust
specifications if needed.
Secondary Cause Facility Location
Closed-Loop system
80/20 Rule
(unseen measures vs seen)SD143 - QA

2. METHOD Production
Instruction
Error Proofing Projects - Workstation Documents
SAFETY
Job Hazard Analysis
PPE Assessment
Ergonomics
Assessment
Particulate Flow
Diagrams Traceability
Reaction Plan /
Flowcharts
In-Line / Off-Line QC
Checks
Industry Standards /
Line Layout / Op
Preventive Maint.
1
2
COMMUNICATION
SCALE
(just the right information needed)
All specific to one machine...
Color code by department
SAFETY
QUALITY
CONTROL
PRODUCTION
ENGINEERING /
MAINTENANCE
OPERATOR
TRAINING
Industry Standards /
QC Alerts / Reports
Calibration
Certificates
Preventive Maint.
Startup Procedures
Standardized Work
Machine Operating
Manual
Reporting / Repair
Procedures
Assembly Parts /
Drawings
Machine Parameters /
Schematics
Spare Parts List
PM Schedules
/Lubricants
Lockout Tag Out
Procedures
Material Handling /
Staging
EHS
Setup Procedures /
Machine Operation
Product QC /
Common Defects
Packaging & Staging
Finished Goods /
Shipping
3
4
5SD143 - QA

3. METHOD Production
Instruction
Error Proofing - Standardized Work Development
EXISTING INDUSTRY
STANDARDS
Line Layout / Op
Preventive Maint.
Startup Procedures
Standardized Work
Machine Operating
Manual
Reporting / Repair
Procedures
3 PREVIOUS STUDIES
(Do not reinvent the wheel)
INTERNAL STUDIES (R&D)
(for practical applications)
MATERIAL VENDORS /
SUPPLIERS
(additional input - capabilities / limits)
MACHINE VENDORS
(additional input capabilities / limits)
ESTABLISH PROCESS
CAPABILITY
CUSTOMER EXPECTATIONS
(Higher Standard than norm)
007OL2
GL2
001
002
003
004
005
006
L4
A-2
BL3
IL2
NL4
Line 2
C-25Production
Engineering
Maintenance
B1
I4
N5
G5
O2
Administration
Quality Control
Quality Control
Quality Control
Miami (MI)
Welding
Fabricatrion 2
Shipping
Warehouse
Storage
Chemicals
San Diego (SD)
Los Angeles (LA)
San Francisco (SF)
Monterey Bay (MB)
Corpus Christi (CC)
Houston (HT)
Shipping
LOCATION FACILITY (I/A) DEPT. SEQUENCELINE / CELL WORK STATION
CAPABILITY
DEVELOP STANDARD WORK
IMPLEMENT TRAINING PROGRAM
(showing the WHY)
***Numbering / Code scheme
follow mapping sequence to
narrow down where it is located
or refers to, just like an address
on a map...
SD-WLD-EG-L2-04-001
SD143 - QA
Can use numbers to be consistent
with accounting...

4. METHOD - PROCESS FLOW Production Instruction
Flow in One General Direction - Error Proofing Projects
MORE MOVEMENT = MORE
ROOM FOR ERROR
6am-
WEST DOCK (NORTH)
NORTHEAST DOCK
Each door represent time frame for
shipping out. Out of time frame and door
EARLY
Drivers that show up
early must be advised
that pickup time starts
as scheduled.
Companies charge
after waiting 2 hours &
$300 if truck is
cancelled too late (last
10am-12pm
WEST DOCK (SOUTH)
Incoming raw goods that are
not used often in assembly.
QC LAB
PARTS - ABC ANALYSIS
SD143 - QA
RG - ABC ANALYSIS
WEST DOCK (NORTH)
Incoming raw goods that are
used often in assembly.
To stock location
Stock to Line side
In Process (Assembly)
WIP (to next line / work cell)
To final staging
Load trucks / Ship
DIVIDE IN TO SECTIONS TO
DETERMINE FLOW

5. METHOD - FACILITY GO / NO GO GAGES
Production
Instruction
Where QC meets Production Demands - Error Proofing Projects
Thread Length Gage
8 5 2
GAGE DEVELOPMENT
1. Design Products / Design
GO/NG Gages too
2. Critical measured areas
3. Write procedures for using
gages & establish frequency.
4. Hang on shadow boards with
workstation tools.
5. Train Operators
Mating Parts: Male side gage
(Holes) and female side (plugs)
#6
Plug gage
Gaps (Feeler gages)
CUSTOM TO ALL
SHAPES / SIZES
Length (+tolerance)
Tank
Shape
SD143 - QA
Thread Gage
BEND ANGLE /
MANDREL DIAMETER
Ø 5"
180⁰
Ø 6"
135⁰
Ø 6.5"
90º

6. MACHINE INTRO
Maintenance
Instruction
Error Proofing Projects - Break up by components
Manufacturer Label
Catalog machine in CMMS. Enter
top consumables and equivalents
(assures right parts replaced down
the road). Capacity meets machine
specifications / needs.
A2
SAFETY ITEMS
JHA (Machine Guards, PPE, etc.), protect
components too like air hoses and
hydraulic lines so they do not get damaged.
Vibration Control & Noise Reduction Mount
[ISO 10816]
LUBRICANTS
DO NOT lubricate posted if needed. Create line diagrams
with ideal angles / bow on line for least wear, etc.
Oil, grease, etc. best for application calculated and posted.
Drip / feed rate posted and marked out on dials. Create
dial marks if none present.. One mark for each products
application that you manufacture.
SENSORS / ALARMS
Draw attention to something you do
not pay attention to 88 out of 90 times
a day (example).
Setup
Easy to follow instructions (1
page with images) for each
product you manufacture.
1. List problems / issues with machine (safety, QC, production, etc.)
2. List countermeasures (PFMEA)
3. Create error-proof ways for awareness and prevention.
4. Measures include: Documentation, Sensors and alarms, custom Gages, etc.
TEMPERATURE CONTROLS
Calculate allowable ranges. Post on machine.
Place temp label add sensors and alarms.
MECHANICAL
Wear conponents on PM schedule.
Speeds adjusted to match company
schedule and application.
Controls marked out. Lockout dials.
Heat treat parts if applicable.
MAX 150⁰⁰⁰⁰
PNEUMATIC
Add pressure gages and mark out parameters, outline air
hoses coming & going and routed throughout the
machine. Create air flow diagrams to make errors stand
out more. Calculate best hose angle / bow and install
holders / guides. Best connectors for application & guard
against damage.
FASTENERS / CONNECTORS
Type and size posted. Torque limits
calculated and posted. Quick release or
not. Replace with wing nut or not.
CP48 ELECTRICAL
Number scheme label. Panel box machine
leads to labeled. Voltage range. 3 Phase.
Schematics created. Amps, Hazard
Labels, etc. Temp Controlled
COOLANTS
Hydro fluid, cooling fluids, water (see water
system), etc. best for application calculated
and posted.
HOSES
Label entry and exit points, whether changing over or not. Color
scheme based on your own uses. Stock hoses are same and
pre-measured. Create line routing diagrams with ideal angles /
bow on line for least wear, etc.
Spray Tips
Whether cooling water, lubricant.,
protective coating, or finish coat, the fan
pattern, angle, and amount of spray are
critical in the quality of end product.
Research best options for you product(s).
SD143 - QA

7. MACHINE - FACILITY WATER
Maintenance
Instruction
Temperature, Pressure, Composition, Flow / Direction - Error Proofing Projects
Actuator (ERIE)
Main water line / Flow limit
300psi / 160⁰F
Water Pressure Gage
Max should be almost twice your needed
range. Range marked to assure within
operating pressure. Some meters cannot
work outside 3gpm
Conductivity Controller ALARM
Set at ideal levels for induction coils. Alarm notifies
when outside levels & need to address.
WATER VALVES
Opened at ideal point to allow water flow at rate needed.
Too little leads to overheating. Too much can cause leaks
or hard water build up.
Water Flow Direction
Mark on pipes near valves to help
troubleshoot leaks, etc.
CoolingWater
Temperature Control Unit (JCI)
Can shut down cooling system if water goes
beyond set point. Range -30 - 212⁰F
1
NOTE (EXAMPLES):
*Valves should be fully open (handle in direction of pipe)
*Cooling Water should be 70-80⁰ degrees max (>95⁰ = Work Order).
*Water Pressure should be 30psi.
*Heat exchangers - Need to cool down (temp gage) first before turning
off. Bad for water and builds up deposits in tubing.
*Need ALARMS for conductivity, temperature, and fill levels.
Spray Nozzles
Reduce build-up of hard water and prevent from clogging
(leads to damaged products too hot for handling).
Solenoid Valve (ASCO)
Flow controls & signal to TDS Meter
Routing Diagram
Make sure all components are in
proper place. to be effective.
2
345
Pump feeder
TDS Meter sends feed signal. Dial set
at feed rate needed. Keeps TDS down
and lines cleaner. Mark feed rate range
on dial.
Cooling WaterWELD1
Label: Machine goes to
Faster troubleshooting for spot
welders, heat exchangers, induction
coils, quench tanks, etc.
ADD VISUAL
ALARMS
ADD ALARM
SD143 - QA
--OPEN--
--Closed--
Float Ball
Keep fill level where needed.
Pumps
Should keep away from bottom
to avoid pumping TDS back in
to system.

8. MACHINE - FACILITY AIR SYSTEMS Maintenance Instruction
Dewpoint, Pressure, Composition (Dryness), Flow / Direction - Error Proofing Projects
Air Filters
Adjust PM Schedules to replace if needed.
Label schedule. Remove debris and
contaminants from air lines that can cause
premature machine wear.
Differential Pressure gages
Mark a marginal area (early warning) and
MAX pressure on gages.
Air Line Regulator
Label pressure range. Reduce air pressure
from facility compressor. Avoids damage to
parts and regulates spray guns.Air line Lubricant
Mark correct drip rate. Cylinders or any
pneumatic moving parts will stick without
lubricant.
ADD ALARMS
1
Label: Machine goes to
Faster troubleshooting.
Cylinder (Pressure) Labeled
Wrong pressure / cylinder, can damage
parts and wear down components faster
than expected life.
NOTE:
*Valves should fully open / closed
*Flow rate should be ___ cfm.
*Filters changed annually.
*Air line lubricants are set to drip at ___ per hour?
*Air Line regulators reduced to recommended pressure for machine
function. Paint guns at 40psi, weld cylinders at ___, and filter blow
down at 90-100psi.
*Facility compressor output set at 150psi MAX.
Routing Diagram
Assures correct order for air
flow to machines.
2 3 4Compressed AirSHEAR2
Routing Air Lines
Assures correct bow and prevent damage by
adding where guards need to go. Label direction
of flow at connection points.
SD143 - QA
Dewpoint Meters
Monitors levels for you. Connect to alarm inline.
Compres

9. MACHINE - FACILITY PUMPS & MOTORS
Maintenance
Instruction
Error Proofing Projects
Manufacturer Label
Capacity meets machine specifications /
needs. Enter in to CMMS & equivalents.
1
Temperature Label
Numbered
Either for quick reference or
by environment (1-
Standard, 2-Severe, 3-
MAX 150⁰⁰⁰⁰
Label MAX Temp
ø___
CP48-12
Panel box
leads to
ADD ALARMS
SD143 - QA
STANDARD: 8hrs / <104ºF / Clean
SEVERE: 16hrs+ / <122ºF / Moderate Dirt
EXTREME: 16hrs+ / >122ºF / Severe Dirt
LOW TEMP: -20ºF
Vibration Control & Noise Reduction
Mount [ISO 10816]
NOTE (EXAMPLE):
*Store in 50⁰-120⁰ max. No more than 60% relative humidity (rust formation on
bearings). Implement controls.
*Lubrication schedule based on Frame size + RPMs + Severity of Service
(Environment).
*Disconnect motor before lifting.
*Do not lift by motor hardware, use eye-bolts.
*Avoid rapid temperature changes when handling (condensation builds inside).
*Minimum resistance of motor winding insulation is 5 Meg ohms.
*Shock or vibration must not exceed 2 mils maximum at 60 hertz, to prevent the
bearings from brinelling.
*Pumps / Pipes outside storage tanks must be away from bottom to avoid pumping
sediment (TDS / settled material) back in to system.
ø___ fitting
Do Not / Lubricate Sticker
Some bearings do not need lubrication
DO NOT LUBRICATE
LUBRICANT USED 1
Machine Guard in
place?
Polyrex EM (Exxon Mobil)
Label Ports by
Standards Grease
Speed Control
Parameters marked
DC44
Dow Corning DC44 < High Temp Grease (over >122ºF)
<60%RH

10. MACHINE - EQUIPMENT MODIFICATIONS
Maintenance
Instruction
After Market Perfromance Parts Added - Error Proofing Projects
AZO Sieve Screen (PT03102)
For removing clumps of powder out of
the spray system. Helps prevent gun
CONNECTIONS (IN SEQUENCE)
1) Accumulator Vent
2) Infeed Powder Tube from Shuttle
3) Accumulator Powder Inlet #1 (TP1)
4) Accumulator Inlet #2 (TP2)
5) Accumulator Inlet #3 (TP3)
6) Accumulator Inlet #4 (TP4)
7) Trash hopper
8) Injector #1-2 (G01-G02)
9) Injector #3-4 (G03-G04)
10) Injector #5-6 (G05-G06)
11) Injector #7-8 (G07-G08)
12) Grounding Cable
13) IMF Efector
14) Hopper Fluidizing Air Hose
Vent Assist Air fitting
3-250/50
Mini Cyclone
Recycles powder back down in to hopper.
Research options for best flow, based on
material size (gravity).
[1]
[3-6]
[7]
[2]
AZO
Feed Hose
Needs to have grounding wire, durable
to where powder does not wear inside
quickly. Bow is minimal to last longer &
have smoother flow.
Magnetic Separator (FF4600)
Removes metal shards left on frames from
blast cleaning. Helps eliminate Holidays. Part
of start-up checks.
the spray system. Helps prevent gun
clogging and uneven application.
Wears down & tears. Part of start-up
Suction Tube
Sends powder up to injectors and out to spray
guns. Modify length to hover above sediment on
bottom. Wears down over time. On ANNUAL
PM.
IMF Efector
Sensor reads level of powder in
Hopper and tells the shuttle to
send more when low. Has gotten
dirty and failed to work before.
Part of start-up checks.
Fluidizing Membrane
Keeps the powder flowing smoothly and not
allowing to settle. On ANNUAL PM.
Sieve Air Volume Controls (226703)
Parameters marked out to assure air flow is within
the set range. Easy to audit. Keep AZO bearings
from locking up and assures smooth flow.
ITW Gema Injectors (x2)
Has a sleeve inside that wears down and
needs to be blown out daily & replaced
roughly every 3 months. Part of start-up
Connection Points [#]
Number the connection tubes for faster
and accurate changeovers. Operators
cross tubes when changing over and
troubelshooting takes longer.
[12]
[8-9]
[13]
[14]
DAILY
MONTHLY
ANNUALLY
INSPECTION SCHEDULEADD ALARM
[10-11]
GROUNDING
Best methods / Fire Hazards
Wheels
Modify for easier movement during
product changeover.
SD143 - QA

11. MACHINE - DIPPING / COATING OPERATIONS Maintenance Instruction
Dip Tank Coating Applications - Error Proofing Projects
Dipstick Hole
Check tank levels easier.
VOCs / Usage & Evaporation Rate
Agitators
Size (HP) determined by material thickness and volume of tank.
Prevents material from settling on bottom. Heavier material needs
more powerful motors and props. Best practice is either using
pumps on the bottom or 1 prop for every 2-3' deep of material and
1 motor for every 3' surface area. Props must bring sediment
upward as it settles. Downward rotation would push sediment to
bottom.
Coating
Surface Area covered
165' Range
Humidity / Temperature Control Units / Alarms
Notification to bring attention to conditions out of the control limits.
Monitoring becomes too routine and may become neglected. This assures
that measures are taken to prevent coating operations outside allowable
ranges.
Some have ranges (165'+) where you can keep the receiving end in your
office to monitor. Others are capable of connecting to alarms and some are
Data Loggers to see trends and find areas needing improvements.
Tank ID
For repair orders
52s
39s
26s
Zahn 1-4
VOCs / Usage & Evaporation Rate
Air Board regulation (California) requires to keep covered when not in use
and monitor daily. Can use MS Excel to create VOC formulas based on
surface area drop (e.g. 1" = 30gal x__ VOC per gallon).
Establish allowable limits based on permits and mark tank as reference to
NOT exceed that limit per day.
2.5'
Impellers as close to bottom as
possible to lift sediment.
SD143 - QA
Emergency Drain Valve
OSHA did require emergency drain valve. Last
CFR update, it may have been removed. Pipe
diameter had to be based on capacity of tank.
(e.g. 1500g = 3" O.D.)
Viscosity (QC)
Most coatings for dipping only needs to be 1.5-2.0mils thick.
Evaporation of mixed solvents cause to get thicker, leaving
clumps and wasting product. Poor QC. Create a viscosity scale
based on internal studies for thickness results. Measure with Zahn
cup based on suplplier recommendations.
Wet Film Thickness (WFT) Gage
Measures thickness based on solids in
material composition. Create a formula
sheet showing Dry Film Thickness (DFT)
based on wet film thickness.
Wheels
Modify for easier movement during
cleanup / spills.

12. MACHINE - PAINTING / COATING OPERATIONS Maintenance Instruction
Paint Booth Applications - Error Proofing Projects
Humidity / Temperature Control Units / Alarms
Notification to bring attention to conditions out of the control limits. Monitoring
becomes too routine and may become neglected. This assures that measures are
taken to prevent coating operations outside allowable ranges.
Some have ranges (165'+) where you can keep the receiving end in your office to
monitor. Others are capable of connecting to alarms and some are Data Loggers
to see trends and find areas needing improvements.165' Range
Differential Pressure Gage
Mark a marginal area (early warning)
and MAX pressure on gages.
Air Line Regulator
Label pressure range. Reduce air
pressure from facility compressor.
VOCs
MUST use High Volume Low Pressure (HVLP) guns.
Air Board regulation (California) requires to monitor
daily. Can use MS Excel to create VOC formulas based
on how many gallons used (e.g. 2gal x__ VOC per
gallon).
Establish allowable limits based on permits and post at
mixing station as reference to NOT exceed that limit
per day.
SD143 - QA
Dial in Thickness
Coatings for spray applications varies in thickness by
customer needs. Establish what 1 FULL coat should be
(feedback from suplier). Do an internal study based on
best coverage and thickness. Establish a formula sheet for
customer demands.
Can use a Wet Film Thickness (WFT) Gage based on
solids in material composition. Create a formula sheet
Fan Pattern
Based on guns used (HVLP) and your internal
study on thickness, determine what direction
your fan pattern should go & how far away you
need to have the gun. Make a Standard for this
operation / train operators.
pressure from facility compressor.
Regulates spray guns to assure
operators do not exceed lhigh
volumes (leads to waste & poor
coat quality), even with controls
on the spray guns.

13. MACHINE - FACILITY WELDING
Maintenance
Instruction
Poor Welds / Less Down Time - Error Proofing Projects
Program Lockout
Prevents operators from changing
parameters to compensate for other
wear items or poor setup.
~ Resistance Welder ~
Wire Feeder
Post Wire feed speed ranges & voltage (AUDIT) to better
control process. Multiple weld stations close to each other
should be labeled to distinguish which weld gun the wire runs
to. Place out of way on swivel so operators can move back &
forth to weld jigs. Use best parts to avoid tangles.
Program
Must stop if weld undetected.
Electrodes / Shunts
Welder
Voltage & Amp range marked to assure
within limit based on material thickness.
Easier for QC Audits.
645645645645 234234234234
Cooling Water
Refer to facility water sheet.
1
Weld Map (Trim Masters Inc.)
Location of welds & assign weld numbers based on
electrode it came from. Faster troubelshooting when
analyzing a weld failure. Weld length legend to show
length of welds by color. Subparts & thickness listed
for voltage needed.
NOTE(s): EXAMPLE
*Shunt type / size / locations should be labeled to assure
correct replacement
*Shielding gas flow rate should be ___ cfm. .
*Wled Condition sheet (parameters determined) placed in
SOP Binder for reference / audits.
Electrodes / Shunts
Boundary samples to establish wear points
and stock replacements.
Routng diagrams
Proper grounding and workpiece position.
Proper bow for weld gun cable (liner - use
spring accessory).
W1-030110-S1-045
For multiple weld stations, assign an ID number to trace
what welder and operator it came from. This can be a label
placed on the rack the products are stacked on.
Example: Welder 1, March 10th, 1st Shift, Operator 045
Liner Bow / Angle
Reduces wear on cable, reducing
tangles (downtime) and
extending life.
SD143 - QA
Weld Curtains
2' off ground (ventilation).
Tinted (flash) / Retractable?

14. MACHINE - CONVEYORS
Maintenance
Instruction
Markers, Material, Sensors & Alarms - Error Proofing Projects
SPACING
Shape Detection
Optical micrometers.
Verifies correct shape.
Time Sensitive (Curing / Cooling)
When using timers, being able to see conveyor marks
lining up with products coming out of an oven, powder
booth, shear, etc, assures correct parameters (settings).
Easier to audit when walking by the line.
Material
Static free, high / low temperature, high
strength, cut resistant, chemical resistant,
flame retardent, high / low friction, etc. Best for
application
MarkersMotion
Alignment
When parts / products are a designated
width or start moving off to the side &
Temperature Check / Counter
Connected to nozzles, sprinklers, air knives, heaters, etc
to cool or heat products before offloading, if temperature
outside of proper range.
SYSTEM CONFIGURATION (OPTIONS)
8" 16" 20"
Weight Sensors
SD143 - QA
Markers
Quick reference to assure
correct lengths of products,
correct spacing, etc.
Light Curtains
Besides safety, also used to detect
overstacking (height limits), height
variations, etc.
Spacing
Verify products are
traveling evenly.
Motion
JAM detection. Sets alert if
products are not moving &
conveyor is.
width or start moving off to the side &
need to fit into another stage, alerts
before they jam.
Metal Detector
Non-metallic materials,
pertinent to not contain metals.

15. High Low PrecipitationRelative HumidityDewpoint
January 53 37 2.2 83 40
February 59 39 1.8 76 42
March 66 42 1.7 68 42
April 73 46 1 60 45
May 80 51 0.5 52 47
June 88 55 0.1 46 49
July 94 58 0 41 52
ENVIRONMENT - FORECASTING Production
Instruction
HIGHS, LOWS, PRECIPITATION, RELATIVE HUMIDITY, DEWPOINT
United States Average Temperatures
Facility Location
California Annual Average
60
70
80
90
100
Precipitation
Reduce Temp
Controls
Increase Temp
Controls
July 94 58 0 41 52
August 92 57 0 45 52
September 87 54 0.2 51 52
October 77 48 0.5 57 47
November 65 40 1.1 70 42
December 55 37 2 81 40
FIELD SUPERVISOR EQUIPMENT SUPERVISOR QUALITY SUPERVISOR TEAM LEAD AUTHOR(s) Doc# LA-SFD-QA-310-028
Ron Fife Rev 1
DATE DATE DATE DATE DATE: 12.05.1996 DATE: 09.09.1998
Facility Location
California Annual Average
Precipitation 1961-1990
0
10
20
30
40
50
60 High
Low
Relative Humidity
Dewpoint
Temperature(Degrees)
SD143 - QA

16. Easy to Follow Controls - Error Proofing Projects
AIR VOLUME: Factory recommended setting is 4.0
Nm³/h with a 60% Powder Output (we use 3.5
Nm³/h with 30%)
KV's: High Voltage setting. Factory Preset with #8
in 100 to wrap the bars more consistently.
RINSING AIR: Based on Nozzle Used (air flow is
measured in Nm³/h). Use SELECT (#9) to navigate
here. Should be 0.2 for our use.
POWDER INPUT RATE: Changes the amount of
powder flow for THICKNESS. Range should be 30-
60% MAX by bar size.
MICRO-AMPS: Controls the Spraying Current.
Factory Preset with #8 is 22µA. Helps conformity
and coating thickness consistency.
MAN - TRAINING / DIRECTION Production
Instruction
2
11
2
5
3
4
3
4
5
7
9
6
10
SELECT: Use with #5. Switch between display
levels. Navigates to Rinsing Air (top right) and
Shaping Air (optional) setting on the Injectors.
REMOTE PLC CONTROL: Not applicable with our
use or processes.
POWER: Used when only running a couple guns.
Otherwise MAIN Power shut down is used. Dowel
Ends only will apply to this.
PROGRAM NUMBER: These are preset based on
Process Capability studies and should not be
changed without QC Approval.
PROGRAM CHANGE: This is part of Set-Up
procedures based on Basket SIZE. Follow your
Parameters Guide (Program Settings).
APPLICATION MODE: Used for complicated parts
with depressions (PROFILES). This is what we use.
Guns MUST be at 8" away.
here. Should be 0.2 for our use.7
8
6
7
8
9
10
11
11
IF COATING THICKNESS
CHANGES, VERIFY SETTNGS. DO NOT
CHANGE THEM UNLESS THEY DO NOT
MATCH PARAMETERS GUIDE.
TROUBELSHOOT HEAT AND CONVEYOR
SPEED NEXT...
LA-310-PNT-019 Rev. 0 1/13/14

17. START: Must be on HOME Screen. Used to initiate
induction heating from panel. The HeatOn light (#11)
will come on.
STOP: Halts the induction heating operation.
Easy to Follow Controls - Error Proofing Projects
MAN - TRAINING / DIRECTION Production
Instruction
SOFT BUTTONS: Used to select specific features.
Operators do not use these buttons, only
maintenance and supervisors.
HOME: Use this button to take you back to the Home
screen.
SELECT: Use Select buttons to highlight SETPOINT or
2
1
3
4
3
4
6
10
7
8
9
11
5
SELECT: Use Select buttons to highlight SETPOINT or
TIMER and to scroll through onscreen lists.
ADJUST: Use these buttons to adjust on-screen
figures such as SETPOINT, TIMER, etc.
FREQUENCY: This is the RF output frequency when
HeatOn. It is the resonant operating frequency.
TIMER: Used to count-up, count-down, or
continuous. Note (T) timer or (C) count up displayed
near arrow.
SET POINT: Output level based on heat required.
Varies by bar size & line speed. Refer to chart. Use
◄/► buttons to increase or decrease.
OUTPUT: V or kW when heating in progess. Higher #
equals faster heating / hotter parts. Use ◄/►
buttons to increase or decrease.
STATUS: Ready, Heat On, Limiting, and Fault. See LED
lights displays to the left.
1 52
6
7
8
9
10
11
READY: EKOHEAT is waiting to heat; no
faults detected.
HEAT ON: START command
received, outputting power per settings.
FAULT: Heating interrupted; fault
detected; correction required. Read
display for information about the Fault.
LIMITING: Either the Voltage, Power or
Temperature values have reached their
maximum limits.

18. START: Used to initiate induction heating from panel.
TEMP DIAL: Set the temperature of the oven based on
BAR SIZE. Follow parameter sheet posted at the
workstation.
STOP: Halts the induction heating operation.
POWER ON / OFF: Main power that needs to be ON
before starting machine.
MAIN BREAKER ENABLE: If the main breaker is tripped,
and then reset, the light will come on.
MAN - TRAINING / DIRECTION
Easy to Follow - Error Proofing Projects
Production
Instruction
2
1
1
3
4
3
4
5
6 7
8
9
5
GROUND CURRENT: Must stay within 0.1 - 0.8 during
normal operation. If meter reads higher, check grounding of
the bars.
GROUND / GROUND RESET: If light is on, the ground
needs to be reset. Check the grounding of the bars.
READOUT DISPLAY: % VOLTS (80-85), % AMPS (90-95),
% KW (80-85), CONDUCTANCE (120-125), FREQUENCY
(944-950), & FAULT CODE.
TEMPERATURE PRESSURE METER: Goes with #8. Will
show the readout based on position selected.
POSITION 1) Inside Air Temp <100⁰F, 2) Inlet Water
Temp <90⁰F, 3) Inlet water pressure 50-60PSI, 4) Outlet
water Pressure 3-5PSI.
10
2
6
7
8
9
10
100⁰
90⁰80⁰
70⁰
MAX 90⁰INLET - from Heat Exchanger
OUTLET - to Heat Exchanger

19. (1) MATERIAL HANDLER
1. Operator sees he is getting low on material.
2. Moves switch to "Material Handler" & turns ON.
3. Material Handler light comes on & unique sound activated.
4. Material Handler comes over and loads infeed to keep line running.
(2) MAINTENANCE
1. Operator needs maintenance support.
3. Maintenance light comes on & unique sound activated.
4. Mechanic arrives to assist and repair machine.
(3) SUPERVISOR
1. Operator needs a Supervisor to escalate a situation.
2. Does not leave workstation to look for mechanic. Moves switch to Maintenance & turns ON.
Clears area to prepare for mechanic.
ANDONS - WORKSTATION
Material
Handler
Maintenance
Supervisor
ON
OFF
1. Operator needs a Supervisor to escalate a situation.
2. Does not leave workstation. Activates Andon, etc…
1
2
3
SD143 - QA

20. (1) MATERIAL HANDLER
1. Operator sees he is getting low on material.
2. Moves switch to "Material Handler" & turns ON.
3. Material Handler light comes on & unique sound activated.
4. Material Handler comes over and loads infeed to keep line running.
(2) MAINTENANCE
1. Operator needs maintenance support.
3. Maintenance light comes on & unique sound activated.
4. Mechanic arrives to assist and repair machine.
(3) SUPERVISOR
1. Operator needs a Supervisor to escalate a situation.
2. Does not leave workstation to look for mechanic. Moves switch to Maintenance & turns
ON. Clears area to prepare for mechanic.
ANDONS - COMM BOARDS
Material
Handler
Maintenance
Supervisor
ON
OFF
1. Operator needs a Supervisor to escalate a situation.
2. Does not leave workstation. Activates Andon, etc…
***Large Communication boards are located in a centralized area and
visible to all employees. The Workstation would light up with a unique
sound (related to personnel needed), indicating the workstation
needed assistance. This was in case the personnel needed were too
far away from the area.
Press 01
Press 02
Press 03
Saw 01
Saw 02
Welder 01 Plasma Cttr Bender 1
Welder 02 Laser Cttr Bender 2
Welder 03 Threader 1 Tapper 1
Welder 04 Threader 2 Tapper 2
Welder 04 Punch ShearN
SD143 - QA