{"id":4391,"date":"2016-05-13T11:23:55","date_gmt":"2016-05-13T08:23:55","guid":{"rendered":"https:\/\/www.glastory.net\/?p=4391"},"modified":"2024-12-02T15:54:56","modified_gmt":"2024-12-02T13:54:56","slug":"finding-root-cause-jumping-conclusions","status":"publish","type":"post","link":"https:\/\/www.glastory.net\/fi\/finding-root-cause-jumping-conclusions\/","title":{"rendered":"Finding the root cause before jumping to conclusions"},"content":{"rendered":"<p>This is a real life story that represents a very common situation at many glass processing factories. It\u2019s a story of making things right with what you have and really digging in to find the root cause of your business or production challenge. If you are a glass tempering line operator, you can find a couple of practical hints. If you are a business manager, you can reflect on whether this is the situation in your factory.<\/p>\n<p>A couple of weeks back, I visited one of our existing glass tempering line customers. They have an approximately 10-year-old flat tempering furnace from Glaston, formerly Tamglass. Since their business has been good thanks to the furnace, the company is now planning to make its next tempering line investment. We started talking about the current market needs, and how those affect the requirements of today\u2019s tempering line investment.<\/p>\n<p>We talked about the new temperable soft coatings with emissivity of 0.01, the trend for larger glass sizes, new thin glass applications, today\u2019s quality requirements for tempered glass, energy consumption, the growing competition, the importance of cost control \u2013 and many other things that need to be considered when making a tempering line investment.<\/p>\n<p>At some point, our customer mentioned as a side note that he has challenges with an approximate 2 x 3 m, 6 mm black tinted glass. I told him that he should not have any challenges, since the machine is more than capable of running that glass size. So we went to see the machine together.<\/p>\n<h3>Defining the problem<\/h3>\n<p>As we came to the unloading table, it was easy to spot that the glass had terrible roller wave and was bent. We went on to the operating panel and looked at the recipe:<\/p>\n<ul>\n<li>Heating time: 280 s (for 6 mm glass that is more than 46 s\/mm) \u2013 unusually long<\/li>\n<li>Furnace max temperatures: approximately 730 \u00b0C \u2013 unusually high<\/li>\n<li>Quench section air balance between top and bottom: 37% \u2013 unusually high<\/li>\n<\/ul>\n<p>I\u00a0asked the operator if there was a reason why he was using such a long heating time and high furnace temperature. The answer was: \u201cIf I decrease the heating time or the temperature, the glass starts to break.\u201d<\/p>\n<div id=\"attachment_4396\" style=\"width: 310px\" class=\"wp-caption alignnone\"><img aria-describedby=\"caption-attachment-4396\" decoding=\"async\" loading=\"lazy\" class=\"size-medium wp-image-4396 lazyload\" src=\"data:image\/gif;base64,R0lGODlhAQABAAAAACH5BAEKAAEALAAAAAABAAEAAAICTAEAOw==\" data-src=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/Roller-wave-300x117.jpg\" alt=\"Roller wave in glass\" width=\"300\" height=\"117\" data-sizes=\"auto\" data-srcset=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/Roller-wave-300x117.jpg 300w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/Roller-wave.jpg 526w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><noscript><img aria-describedby=\"caption-attachment-4396\" decoding=\"async\" loading=\"lazy\" class=\"size-medium wp-image-4396\" src=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/Roller-wave-300x117.jpg\" alt=\"Roller wave in glass\" width=\"300\" height=\"117\" srcset=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/Roller-wave-300x117.jpg 300w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/Roller-wave.jpg 526w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/noscript><p id=\"caption-attachment-4396\" class=\"wp-caption-text\">Roller wave, image source:\u00a0\u00a9 Glaston<\/p><\/div>\n<p>Searching for the root cause<\/p>\n<p>We walked around the factory before making any adjustments and spotted a clear fault on the pre-processing side. As we passed one grinding machine, almost all the glass pieces of a certain size had a relatively large crack in one specific part of the glass. Then things started to make sense. The operator needed to compensate for the poor edge grinding quality by overheating the glass excessively!<\/p>\n<h3>Getting the process right<\/h3>\n<p>After spotting this we started to tune the recipe. I called to one of our process experts to confirm some parameter levels. The 730\u00a0\u00b0C for that specific glass tempering machine (Glaston-Tamglass HTF Super) the furnace temperature is too high. The first action was to decrease the overall furnace temperature. After this we slowly started to decrease the heating time. At the same time we needed to decrease the air balance (to make the pressure adjustment in the quench section more even).<\/p>\n<p>Earlier, when the glass was so much overheated it was actually bent already when existing the furnace. The high air balance setting tried to overcome this but actually it tried again to correct a mistake that was already made. If you need to run with 37% level air balance there has been already a mistake in the heating section. This advice applies on both clear and tinted glass.<\/p>\n<p><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-medium wp-image-4400 lazyload\" src=\"data:image\/gif;base64,R0lGODlhAQABAAAAACH5BAEKAAEALAAAAAABAAEAAAICTAEAOw==\" data-src=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-300x180.jpg\" alt=\"Glaston operator training\" width=\"300\" height=\"180\" data-sizes=\"auto\" data-srcset=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-300x180.jpg 300w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-768x461.jpg 768w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-1126x676.jpg 1126w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-640x384.jpg 640w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170.jpg 1990w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><noscript><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-medium wp-image-4400\" src=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-300x180.jpg\" alt=\"Glaston operator training\" width=\"300\" height=\"180\" srcset=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-300x180.jpg 300w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-768x461.jpg 768w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-1126x676.jpg 1126w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170-640x384.jpg 640w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/90R3006-e1462872049170.jpg 1990w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/noscript><br \/>\nGetting the process right. Picture source: \u00a9Glaston<\/p>\n<p>This is not the first time I see a tempering line operator (or the line itself) being blamed for a mistake that happened much earlier in the process. This is an advice I can\u2019t stress enough: always do the root cause analysis on the quality problems you have! There are excellent tools for this. One that I really like is the<a href=\"http:\/\/asq.org\/learn-about-quality\/cause-analysis-tools\/overview\/fishbone.html\" target=\"_blank\" rel=\"noopener noreferrer\"> fishbone-diagram, aka cause-and-effect-diagram<\/a>. I\u2019m sure this is familiar to those who have been involved in LEAN manufacturing philosophy.<\/p>\n<h3>Summary<\/h3>\n<p>We know this situation is very common in many glass processing factories. And sadly many of the poor quality glasses end up being installed in buildings. The poor quality always leads to decreased customer satisfaction and decreasing amount of repeat orders. This is why I can\u2019t stress enough the importance of training at all levels of the organization. You can get your internal guys to do the training once in a while or ask for the assistance from the tempering line manufacturer like Glaston.<\/p>\n<p><img decoding=\"async\" loading=\"lazy\" class=\"size-medium wp-image-4393 lazyload\" src=\"data:image\/gif;base64,R0lGODlhAQABAAAAACH5BAEKAAEALAAAAAABAAEAAAICTAEAOw==\" data-src=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2-300x226.png\" alt=\"Example of poor glazing\" width=\"300\" height=\"226\" data-sizes=\"auto\" data-srcset=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2-300x226.png 300w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2-768x580.png 768w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2-640x483.png 640w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2.png 902w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><noscript><img decoding=\"async\" loading=\"lazy\" class=\"size-medium wp-image-4393\" src=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2-300x226.png\" alt=\"Example of poor glazing\" width=\"300\" height=\"226\" srcset=\"https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2-300x226.png 300w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2-768x580.png 768w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2-640x483.png 640w, https:\/\/www.glastory.net\/wp-content\/uploads\/2016\/05\/poor-glazing-2.png 902w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/noscript><br \/>\nPicture source: www.gpd.fi \u00a9M. Patterson, Enclos<\/p>\n<p>Back to this customer\u2019s new line investment: we agreed together to first set the process right for the existing line by arranging a proper training program for all of his operators. Only after this can we better plan the next investment and the best way to split the production between these two lines.<\/p>\n<p>We already know one big difference between the existing line and the new one \u2013 size. Did you know our most-sold glass tempering line size was 2.4 m x 4.8 m just 8 years ago, whereas today it\u2019s 2.8 m x 6.0 m?<\/p>\n<p><strong>PS. The images shown in the article are not related to this particular case.<\/strong><\/p>\n","protected":false},"excerpt":{"rendered":"<p>This is a real life story that represents a very common situation at many glass processing factories. It\u2019s a story of making things right with what you have and really digging in to find the root cause of your business or production challenge. If you are a glass tempering line operator, you can find a [&hellip;]<\/p>\n","protected":false},"author":66,"featured_media":4415,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_exactmetrics_skip_tracking":false,"_exactmetrics_sitenote_active":false,"_exactmetrics_sitenote_note":"","_exactmetrics_sitenote_category":0,"_uf_show_specific_survey":0,"_uf_disable_surveys":false,"ngg_post_thumbnail":0,"footnotes":""},"categories":[11],"tags":[9,1160,264,81,71,10,194,111,265,121,190,15,261],"acf":[],"aioseo_notices":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v19.4 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Finding the root cause before jumping to conclusions &ndash; Glastory<\/title>\n<meta name=\"description\" content=\"This is a story of making things right with what you have and really dig in to find your the root cause of your business\/production challenge.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.glastory.net\/finding-root-cause-jumping-conclusions\/\" \/>\n<meta property=\"og:locale\" content=\"fi_FI\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Finding the root cause before jumping to conclusions &ndash; 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