As evolution has taken its course, only the most resilient species have survived, resulting in a genetic line that is highly resistant to various challenges.
Strategy of planned obsolescence in products to encourage repeat purchases and drive consumer spending.
Five years ago, I found myself in a sterile cleanroom adorned in a "bunny suit" on a sweltering August day near the Sea of Japan, nestled between Osaka and Kobe. I vividly recall hunching over a machine frame's cutout, where we ingeniously housed controls within empty spaces instead of traditional control cabinets. In the dimly lit room, I noticed the safety relay's input LEDs pulsating intermittently, resembling steady breaths. Despite the main disconnect powering down the machinery, adjacent equipment, and even the entire building, the LEDs continued their sporadic dance. Through trial and error, I managed to resolve the nuisance-tripping issue by incorporating an RC network to counteract the induced voltage in the e-stop series circuit. While this troubleshooting episode was frustratingly inexplicable, I successfully conquered the challenge. This bizarre incident serves as a memorable reminder of my expertise in handling unforeseen technical anomalies in the field.
unsaint33 posed a curious question regarding a common occurrence in manufacturing plants. Despite producing thermostat devices with mostly in-house parts, their various machines, both new and old, seem to experience similar issues within a short timeframe. For instance, within just 2 or 3 days, four different machines required service due to faulty limit switches. This trend also extends to photoeyes and safety relays. It seems to be the nature of the industry they work in.
Every single one of the limit switches was faulty, a common issue that frequently occurs with photoeyes and safety relays. It is possible that the constant malfunctions of the limit switches and photoeyes could be attributed to a specific forklift operator frequently operating in the area. Just like the black cloud that follows Joe Btfsplk in Li'l Abner, equipment failures seem to gravitate towards certain operators.
One possible reason for this phenomenon is that our minds have a natural inclination to find patterns in the world around us. However, we often struggle with statistics on the fly. Have you ever bumped into a friend in a city by chance and exclaimed "small world"? In reality, this occurrence is not as rare as it seems - we simply overlook the countless other random encounters we have daily.
Rob suggests that our minds tend to seek patterns in things, a common trait among humans. While we may not excel at statistical analysis on the spot, we often find ourselves marveling at seemingly coincidental encounters with friends in unexpected places. This phenomenon can be attributed to our selective memory, as we tend to overlook the countless other chance encounters we have daily. Ultimately, it is up to individuals to decipher the underlying reasons behind these occurrences.
The machine spirit at my plant appears to have its quirks. It seems to have a displeasure for certain things, such as replacing outdated parts with newer ones, operating at a slower pace, and keeping its gears greased. On the other hand, it thrives on operating at full capacity non-stop, having control panels filled with rapidly switching relays, and being covered in a layer of dust.
It has been observed that when production targets match the machine's maximum capacity, it operates flawlessly. However, when targets are set lower, breakdowns occur frequently, often involving hard-to-find parts in today's technological age. This emphasizes the importance of running the machine at full throttle to keep it happy and efficient.
I once encountered a superstitious colleague who took his beliefs very seriously. Every time a new machine was installed, he would sprinkle holy water on it. A similar incident occurred when I was working in offshore drilling in West Africa, where our winches had proximity switches to ensure safety. One Sunday, multiple switches failed in succession, causing a major issue. Despite not having enough spares on hand, I managed to keep the machines running by improvising with available resources. Interestingly, a neighboring ship faced a similar problem with their switches, leading us to discover that the tropical weather had likely caused the malfunctions. Despite the stressful situation, I successfully replaced the faulty switches without any downtime, making it a challenging yet rewarding experience.
Ken Roach reminisced about a scorching summer day five years ago when he was clad in a cleanroom "bunny suit" near the Sea of Japan, sandwiched between Osaka and Kobe. Having experienced the intense heat and humidity in Osaka during August firsthand, he exclaimed "Godzilla" and expressed relief at not being in Tokyo during that time.
IO_Rack mentioned their recent trip to Osaka in August and described the weather as brutal. Another commenter agreed, stating that the heat and humidity in Osaka during August can be truly horrendous.
In central Wisconsin, it's common to find that 90% of the local industrial sites are located on sacred Native American burial grounds, adding an element of mystery and intrigue to the area. Additionally, sightings of gremlins are frequently reported in the region.
- 08-01-2025
- WhinnieThePooh
During my time at a shop, the manager meticulously recorded all instances of machine breakdowns - focusing solely on the frequency of each machine's malfunctions, and not on my response or repair times. He summoned me when he noticed a recurring pattern throughout the shop: whenever one machine or production line was repaired, a neighboring machine would immediately experience a breakdown. For instance, if the loader on a line was back up and running, the unloader would then malfunction. Despite there being no evident connection between the machines, I amusingly suggested to him that it might be due to jealousy - as if the other machines were envious of the attention being given to their counterparts. In jest, I asserted that this was the only plausible explanation, as no other logical reason could be identified.
Early in my career, I had the opportunity to work on a customized Automated Storage and Retrieval System (ASRS) for handling particleboard stacks. Located in Sault Ste. Marie, one interesting challenge arose after the system was up and running. Users reported that the storage cart seemed to be hesitant around the new forklifts. Surprisingly, it would unexpectedly veer off in another direction when approached by these modern vehicles, unlike the older ones.
The ASRS was equipped with a sophisticated long-range retroreflective laser sensor to accurately track the storage cart's movements. However, the placement of the reflectors on the wall across a busy aisle caused some issues. While I had programmed the sensor to recognize and overlook obstacles like people, vehicles, and obstructions, I overlooked the possibility of it detecting reflections from the reflective tape on the new forklifts. This unintentional oversight was causing the storage cart to behave erratically in the presence of these high-viz trucks.
I was recently involved in a commissioning project with the assistance of a graduate engineer. The project involved utilizing roller conveyors to move tubs in specific patterns. Interestingly, whenever I observed the conveyors, they operated flawlessly. However, when my graduate took over, issues would arise. It turned out that despite calibrating all the proximity sensors to only detect objects 100mm away, the reflective strips on his new hi-vis vest were so bright and clean that they would trigger the sensors from a distance of over a meter, causing the conveyors to react and divert the tubs in the wrong direction. This unexpected issue taught us the importance of considering all variables when setting up automated systems.
Two decades ago, when a machine would suddenly come to a halt, the light curtain would flicker. I would align, test, and realign the components, thinking I had fixed the issue. However, within a few days, the same problem would resurface. I would replace components with the same brand and type, but the issue persisted. After seeking advice from the light curtain manufacturer, I was instructed to cover the light curtain receiver with a "GREEN" trash bag. Surprisingly, the problem disappeared for a period of two weeks. Upon removing the trash bag, the issue returned. It turned out that the strobe light was causing interference with the existing light curtain, particularly when the crane was loading a specific machine. It was a unique and significant discovery, only occurring under specific circumstances when everything aligned perfectly.
Cardosocea shared a story about their experience working in offshore drilling in West Africa, where they encountered issues with P+F proximity switches failing due to the tropical weather. Despite initially trying to troubleshoot and replace the faulty switches, they ultimately had to source replacements from a nearby ship experiencing similar problems. Additionally, they faced similar challenges with Festo reed cylinder switches, which failed due to inadequate temperature and humidity ratings for the environment. This led to a mass replacement of switches to ensure smooth operations in their equipment. Both incidents highlight the importance of using components that are suited for the specific environmental conditions in offshore drilling operations.
During the early stages of my career, I worked on a custom Automated Storage and Retrieval System (ASRS) for particleboard stacks at a facility in Sault Ste. Marie. One interesting issue arose after the system was up and running - the storage cart seemed to be "fearful" of the new forklifts. Surprisingly, whenever one of the new forklifts passed by, the cart would unexpectedly veer in the opposite direction, which didn't occur with the older Hysters.
The ASRS utilized a long-range retroreflective laser distance sensor to locate the storage cart, with reflectors placed on a wall across a cargo and personnel aisle. While I had programmed the sensor to disregard obstacles like people, vehicles, and stacks of particleboard, I had overlooked the reflection caused by the high-visibility sticker tape on the new forklift fleet.
I encountered similar challenges with photoeye sensors on different conveyor systems. One instance involved a conveyor that suddenly began unloading products non-stop due to a high-bay light positioned directly above the photoeye. Another situation occurred at a spray coating line, where the photoeye struggled to detect panels due to the flat black color of the sprayed product.
In both cases, strategic adjustments and problem-solving techniques were required to resolve these issues and ensure smooth operations within the facility.