1、TROUBLESHOOTING VIA THE FISHBONE DIAGRAM METHOD鱼骨图法用于分析金属加工冷却液常见问题 What are Fishbone Diagram? 何为鱼骨图? The Fishbone Diagram is a tool used to systematically investigate possible causes of problems. The ones included in this manual covers 8 problems common in water-based metalworking coolant applicatio
2、ns. 作为分析问题的工具,鱼骨图法可以系统地分析问题的成因.本介绍主要就冷却液使用和维护过程中常见的八种现象运用鱼骨图法加以分析. Odors 异味 Dermatitis 皮肤接触炎症 Foam 泡沫 Poor Tool Life or Finish 非正常加工刀具使用寿命或加工工件表面质量下降 Rust 工件绣蚀 High Coolant Consumption 高冷却液消耗 Unacceptable Residues 工件或刀具表面残留物 Change in pH 冷却液酸碱度变化 When confronted with one of these problems, work your
3、 way through the Fishbone Diagram that addresses it. You will identify the source of the problem by asking questions and eliminating potential causes that do not apply in your particular case. 对于实际发生的问题可以参照相对应的鱼骨图逐项查找原因.在应用现场,通过提问的形式排除法找出问题之所在. How do I use Fishbone Diagrams? 如何运用鱼骨图? 1. Find the di
4、agram that addresses the problem. The name of the problem is printed at the “head” of the fish (right side of the page). 找出于现场问题相对应的分析图.问题标注在“鱼骨顶部“(图形右侧). 2. Look at the “ribs” protruding from the spine of the fish. These conditions commonly contribute to the problem. Each rib lists several variable
5、s that should be investigated.逐项研究由鱼主椎骨分离出的斜骨.每一斜骨都可能是造成问题的原因. 在每一斜骨上给出的参数和变量应当进行详细的研究. 3. Move down the fishbone from head to tail (right to left) addressing each condition in sequence. The conditions are listed with the most common causes shown closest to the head. All variables must be investigat
6、ed and determined to be in control or in need of correction.将可能产生的原因从头到尾逐相分析.通常容易出现的原因有目的的放在靠近鱼头的位置.所有列出的原因和变量必须加以研究以达到有效控制和对出现问题的及时修正.,绣蚀或斑痕RUST OR,STAIN,Packaging 包装,Uneven Coating 冷却液覆盖不完全,(Dewetting, Clogged Nozzles),Storage Conditions 仓储状态不佳,(Humidity, Acid Atmosphere),Low Coating Weight 冷却液成膜差
7、,pH 高酸度,Hardness 高水硬度,Sulfates 硫酸盐含量高,Chlorides 水中氯离子含量高,Contamination 水质污染,补加水 MAKE-UP WATER,现场应用APPLICATION,Residual Contamination,(i.e. Poor Cleaning) 表面杂质,Surface Chlorides 表面氯化物,Pre-Existing Rust/Pitting,工件原有的绣蚀/锈斑,Low Concentration 浓度低,Contamination 外来污染,High Moisture 湿度大,Oxidation Due To,Exce
8、ss Heat高热氧化,High Bacterial Growth 细菌生长,冷却液产品PRODUCT,材料问题SUBSTRATE,Moisture On Surface 表面水分,腐蚀 CORROSION,屑产生量Soil Load,温度Temperature,清洗剂混入 Cleaner Carry In,水硬度Hardness,氯离子Chlorides,外来污染Contamination,补加水MAKE-UP,WATER,工艺过程 PROCESS,喷嘴堵塞Clogged Nozzles,接触时间Contact Time,浓度Concentration,外来污染Contamination,错
9、用Misapplication,防腐蚀添加剂受热分解Loss of Inhibition,Due To Over Heating,温度Temperature,冷却液产品PRODUCT,设备 EQUIPMENT,湿度高 High Humidity,Location In Plant 摆放环境,环境 ENVIRONMENT,pH,pH 变化 CHANGE IN pH,Improper Test Method 检测方法,Slug Additions of Product 产品成块状加入,Improperly Functioning,Pre-mix 产品预混不佳,清洗剂或洗涤液混入系统 Cleaner
10、 Or Soap,工件带入Carry In From Parts,碱性污染 ALKALINE CONTAMINATION,高浓度 HIGH CONCENTRATION,Oxidation/Hydrolysis,Acid Cleaner,Improperly Functioning,Pre-mix 预混效果差,Large Water Additions 水加入量过度,Improper Test Method 检测方法,浓度低LOW CONCENTRATION,酸性污染 ACID CONTAMINATION,Biological Growth,pH 值降低 DECREASE IN pH,pH 值增
11、加 INCREASE IN pH,异味 ODORS,食物 Food,抹布 Shop Towels,香烟头 Cigarettes,外来污染 GROSS CONTAMINATION,工件表面杂质 Coating Coming In On Parts,杂油Tramp Oil,细菌(氨味) Bacteria (Ammonia),厌氧菌 (硫化氢)Anaerobic,Bacteria (Hydrogen Sulfide),霉菌Fungi,生物生长 BIOLOGICAL GROWTH,加工过程污染 PROCESS CONTAMINATION,邻近系统杂质混入,Overflow From Nearby Sy
12、stems,口香糖/烟草Chewing Tobacco,粪便 Human Excrement,刀具寿命下降或加工质量下降,POOR TOOL LIFE OR PART FINISH,流体温度高 Fluid Temp Too High.,冷却液流动不畅 Poor Fluid Flow,气泡量大 Entrained Air (Foam),磨料添充 Wheel Loading,刀具积屑,Build-up On Tooling,杂油量大 Excessive Tramp Oil,清洗性不够 LACK OF,DETERGENCY,冷却不足,INSUFFICIENT COOLING,工艺设计变更 Desig
13、n Change,工件材质变化 (硬度,孔隙率等)Change In Alloy,(Hardness, Porosity),Low Concentration,浓度低,Depletion Of Lubricant,有效润滑成分分解,杂油过多,Excessive Tramp Oil,润滑不足 INSUFFICIENT LUBRICATION,加工工件 PART,校正不精确 Poor Alignment,O.O.S.,Tooling,刀具 TOOLING,供应商变化,New Supplier,浓度太高Concentration,Too High,外来杂油多 Excessive Tramp Oil,
14、清洗成分损失 Depletion of Detergent Additives,冷却液消耗量大 HIGH PRODUCT CONSUMPTION,选错产品 Misapplication,仓储管理混乱,“Borrow” Product Missing Inventory,浓缩液泄漏无记录和处理 Undocumented Or Uncontrolled Spills,操作环境 ENVIRONMENT,加工工件变硬 Harder Part Alloy,喷嘴方向不正确 Misdirected Nozzles,预混不佳 Premix Improperly Set,自动加液装置非正常操作 Auto-Fee
15、d Out-Of-Control,浓度 CONCENTRATION,工艺过程 PROCESS,系统泄漏 Leak In System,冷却系统 SYSTEM,太高 Too High,泡沫 Foam,过度溢流和撇油 Uncontrolled Overflow/Skimming,离心分离不正常 Incorrectly Functioning Centrifuge,泄漏 Leaks,生产量增加 Increase In,Productivity,刀具损耗大 Poor Tooling,残留物超标 UNACCEPTABLE RESIDUES,杂油 Tramp Oil,霉菌生长Fungal Growth,工
16、件夹带杂质 Coating Coming In On Parts,产品消耗量大 Excessive Product Used,过度蒸发 (温度高) Excessive Evap.,(Temp. High),浓度高 High Conc.,产品 PRODUCT,污染 CONTAMINATION,高杂油 High Tramp Oil,乳化剂损失 Depletion OfEmulsifier,高水硬度 High Hardness,High T.D.S.,水质 WATER QUALITY,清洗性下降 LOSS OF DETERGENCY,过滤器选型错误 Wrong Type,过滤系统失灵 Broken,
17、过滤 FILTRATION,操作不正常 Improperly Functioning,液体流入 Fluid Carry In,上道工序变化 Change In Prior Process,采用新产品 New Fluid Involved,工艺 PROCESS,泡沫 FOAM,清洗剂和洗涤液 Cleaner Or Soap,随工件带入 Coating ComingIn On Parts,上一工序带入 Carry In From Previous Process,外来污染 CONTAMINATION,切削/进给速度增加 Increased Speeds/Feeds,泵气蚀 Pump Cavitat
18、ion,水硬度低Low Hardness,配液不充分 Slug Product Additions,产品 PRODUCT,设备 EQUIPMENT,压力,流量增加 Excessive Pressure, Flow, Cascade,浓度高 High Concentration,过量蒸发 Excessive Evaporation,泡沫 FOAM,带入清洗剂Cleaner Carry In,出现皂类物 Soap Formation,污染 Contamination,工艺 PROCESS,泵气蚀 Pump Cavitation,低温Low Temperature,金属屑量Soil Load,产品
19、PRODUCT,设备 EQUIPMENT,循环速度 Recirculation Rate,高浓度 High Concentration,消泡剂量 Defoamer Content,喷嘴压力 Nozzle Pressure,选错产品 Misapplication,补加水 MAKE-UP WATER,污染 (如工艺水) Contamination (i.e. Process Water),软水 Low Hardness,清洗质量不好 POOR CLEANING OR RESIDUE,产生屑量 Soil Load,温度 Temperature,清洗剂随工件带入 Cleaner Carry Into
20、Rinse,工艺 PROCESS,喷嘴堵塞 Blocked Nozzles,温度 Temperature,污染 Contamination,产品 PRODUCT,设备 EQUIPMENT,清洗介质积存于过滤器内 Detergent Stripping In Filter,浓度 Concentration,屑量Soil Load,超声气蚀 Ultrasonic Cavitation,浮油 Oil Float,补加水 MAKE-UP WATER,水硬度变化 Hardness,水中悬浮固体 Suspended Solids,接触时间 Contact Time,喷射形式 Spray Pattern,压
21、力低 Low Pressure,漂洗不佳Poor Rinsing,污染物 Contamination,生产量增加 Increased Production,pH,干燥不合适 Improper Drying,(Blow Off),皮 炎 DERMATITIS,四季变化 (干/冷) Change In Season (Dry/Cold),新雇员 New Employee,环境 ENVIRONMENTAL,直接用溶剂清洗 Solvent Washing,个人卫生 PERSONAL HYGIENE,高 pH HIGH pH,碱性物污染 Alkaline,Contamination,浸油布或衣服 Soi
22、led Rags Or Clothing,无劳动防护服 Lack Of protective Gear,污染 CONTAMINATION,杂油 Tramp Oil,碱性物质 Alkaline,浓度高 High,Concentration,太多 Too Much,使用太频繁 Too Often,使用杀菌剂 BIOCIDE USAGE,生锈RUST,水硬度 Hardness,氯离子 Chlorides,前工序影响Carry In From,Previous Process,杂油 Tramp Oil,细菌生长 High Micro Growth,污染 CONTAMINATION,水质差 POOR W
23、ATER,QUALITY,冷却液量不够 Insufficient Coverage,Of Fluid On Part,金属 Alloy,加入过量水 Large Water,Additions,试验方法 Improper Test,Method for,Concentration,产品 PRODUCT,工艺改变 CHANGE IN PROCESS,仓储条件不好 Poor Location,In Plant,湿度大 High,Humidity,环境 ENVIRONMENT,硫酸盐Sulfates,抗绣蚀剂损失Depletion of Rust,Inhibitors,浓度低 Low,Concentration,
