Problem-solving skills are needed to overcome the wide variety of problems that frequently occur in R&D, pilot and manufacturing coaters. These problems can cover a wide range of deficiencies, such as: physical defects from contamination, coating instability defects, support induced defects, non-uniform coverage, poor drying, installing an additional coating method, and the inability to apply the coating solution. For economic success, the fundamental cause of these problems must be determined and cured rapidly.

To effectively solve these problems, the personnel assigned to the task need to develop skills in the following areas:

• Coating process understanding
• Analytical and measurement instruments
• Information technology
• Communication and listening

The use of a formal strategy is essential in guiding the problem-solving process to an effective long-term solution. This strategy serves as a guide through the process and insures that all of the necessary factors needed to solve and understand the problem cause are considered. It will also prevent jumping to conclusions and wasting resources.

Without the skill to use a formal strategy, the cost to solve the problem will increase and the solution may not be effective or the most appropriate one.

There are many different systems in use and all of them contain the same basic elements:

• Define the problem so that all personnel are in agreement
• Allocate necessary resources
• Obtain data on the problem
• Define options that can lead to the solution and test them
• Determine the root cause of the problem
• Implement permanent solution
• Use above knowledge to prevent further occurrences.

A specific strategy should be selected and personnel trained in this system. There are many texts and training courses available on a variety of effective strategies.

An open-minded approach is a necessary part of any strategy utilized. It is important to consider all possible options and not to reject an option based on past prejudices. History and experience can be a help and it also can be a handicap. The current situation may be entirely different and past data not applicable.

If the data gives you an unexpected result or a novel solution is proposed, consider the merits and act appropriately. Do not automatically reject it.

A coating line is a complex process consisting of several basic hardware modules, all of which can cause quality, capacity and economic problems. Problems in one operation can lead to defects or malfunctions in another step of the process.

For example, tension variations in the web on unwinding can cause coating chatter. Fluid flow instabilities and mechanical vibrations in the coating line hardware can also cause chatter. Changes in the surface tension of the support can lead to coating defects.

Therefore, a fundamental understanding of how each module functions and how they influence each other is essential to determining the cause of coating process problems.

Effective problem-solving requires analytical and measurement skills to characterize the process and defects so that fundamental cause can be determined. Personnel need to understand the capabilities of a variety of techniques so that the appropriate product or process measurements are made. Typical product analytical techniques are optical microscopy, scanning electron microscopy, thickness measurement and thermal analysis. Process measurement techniques needed are rheological measurements such as viscosity, temperature measurement for liquids and gas, velometers, data loggers and tachometers.

Information technology provides a wide range of tools and techniques to obtain information and convert it into useable knowledge. Skills in the utilization of these tools to obtain and process all of the data needed to solve the problem are required. Tools included in this category are:

• Designed experiments to determine effect of process variables
• Statistical techniques to analyze data, such as regression analysis
• Quality control techniques such as control charts to determine process trends
• Continuous improvement tools, such as fishbone diagrams to find causes of problems, and Pareto charts to focus quality-improvement efforts
• Modeling programs to simulate the coating and drying process and reduce the experimentation required.

Skills in communications techniques, audio and videoconferencing technology, computer conferencing and document sharing are needed. The problem-solver must interact with many people, either as individuals or in teams, during all phases of the process.

Therefore, effective communications are needed to obtain and transmit the needed information and to implement action items. The assistance of personnel outside of the group is often needed, and the ability to communicate the problem, and your needs, will speed up the process.

Considerable time and effort can be wasted with a poor communications process. Effective listening is also a needed skill. It is very easy to miss what people are trying to tell you by not listening carefully, or by ignoring what is being said.