--- title: "The 5 M's: Troubleshooting Process Defects" description: Fix recurring molding issues the right way by applying the 5 M’s framework—get better control over quality by isolating the true cause every time. image: https://www.asaclean.com/hubfs/AI-Generated%20Media/Images/This%20image%20depicts%20someone%20writing%20the%20word%20DEFECTS%20and%20circling%20it%20with%20a%20red%20marker.jpeg --- [ Order Online ](https://asaclean.my.site.com/b2bstore) [ Free Sample ](https://offers.asaclean.com/free-sample) ## [ Asaclean Blog ](https://www.asaclean.com/blog) Browse by Topic " aerospace asaclean asaclean news Asaclean® benefits asahi kasei automotive Best Practices black specks blisters blow molding blown-film extrusion buyers caps and closures carbon contamination cast-film extrusion Chemical Purging Compounds clear applications Color Changeovers Company News compounding consumer products contamination Cost savings custom molders Customer Success Story decreasing scrap defects electronics Energy Efficiency EX Grade extruder cleaning Extrusion fillament glass filled Glitter Grade Selection HDPE High and Low Temp Changeovers hold a bubble Hot Runners Injection Molding Injection Molding Tips LDPE Lightweight automotive components LLDPE low residue maintenance Material Changeovers Mechanical Purging Compounds medical Melt Flow Index NPE 24 nylons on the fly packaging PCR PEEK Polypropylene Post Consumer Resins preventative preventative purging processing tips profile extrusion Purge Program purge programs Purge Training Purge Trial purging purging compounds purging concentrates purging procedures Purging Tips quality recycled resins residue issues scrap reduction Screw Pulls sheet extrusion shutdown and sealing start-up super engineering resins Sustainability Tech Day technical support training trials Troubleshooting Twin Screw twin screw extrusion two step purging U Grade ULTEM venting Viscosity webinars wire extrusion - 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[LinkedIn Share ](https://www.linkedin.com/shareArticle?mini=true&url=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Fthe-5-ms-troubleshooting-process-defects&title=The%205%20M%27s%3A%20Troubleshooting%20Process%20Defects&summary=Fix+recurring+molding+issues+the+right+way+by+applying+the+5+M%E2%80%99s+framework%E2%80%94get+better+control+over+quality+by+isolating+the+true+cause+every+time.&source=) - [Pinterest Pin ](https://pinterest.com/pin/create/button/?url=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Fthe-5-ms-troubleshooting-process-defects) - [Email Email ](mailto:?subject=The%205%20M%27s%3A%20Troubleshooting%20Process%20Defects&body=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Fthe-5-ms-troubleshooting-process-defects) ![The 5 M's: Troubleshooting Process Defects](https://www.asaclean.com/hs-fs/hubfs/AI-Generated%20Media/Images/This%20image%20depicts%20someone%20writing%20the%20word%20DEFECTS%20and%20circling%20it%20with%20a%20red%20marker.jpeg?width=640&height=500&name=This%20image%20depicts%20someone%20writing%20the%20word%20DEFECTS%20and%20circling%20it%20with%20a%20red%20marker.jpeg)   ![5ms of process defects](https://www.asaclean.com/hs-fs/hubfs/5ms%20of%20process%20defects.jpg?width=350&height=263&name=5ms%20of%20process%20defects.jpg) Many times when processes go awry the true cause is not identified.  Too often significant changes are made without a just reason behind them, other than the assumption that “I know how to fix that.”  Every technician has a silver bullet and they always think it’s a better fix than the one provided by the previous shift. Before making any major changes to your process, you should always consider the 5 M’s. **1.) MAN** By far, the easiest culprit to identify is #1.  If the process is running in semi-automatic and the cycle time is dependent on the machine operator, this is one of the major factors. Inconsistent cycle time can cause issues with material temperature and residence time variations. This contributes to mold temperature inconsistency, not to mention lost productivity and increased scrap rate. **2.) MACHINE** Look at the actual readings on the machine and not the set points. Are the machine functions (hydraulic / temperature / time) functioning properly? Are the set points met in a normal response time? Once these have been checked, move on to the next M. **3.) METHOD** Is the machine set to the process set up sheet? The slightest variations from the set up sheet can have huge impacts on the process over even a short period of time. A process adjustment log is a great tool to have with the set up sheet / book. Also, process deviations should not be allowed unless explicitly approved by the Process Manager and the book should be updated immediately after the process variation has been approved. **4.) MOLD** The mold should not be a factor if it is maintained,  has had full PM’s performed at its scheduled intervals, and is within its life span of cycles produced. That being said, a tool that is not clean and venting properly will most definitely create problems. Burn marks, splay, bubbles, heavy weld lines, just to name a few. Manifold tools equipped with valve gates (or non-valve gates) that have multiple heaters can be tricky. Identifying the problem area may require data to be collected over a period of time. Scatter / Concentration charts are very helpful in identifying where the problem originates. **5.) MATERIAL** If you're still reading, you may need to ask yourself the following questions: Has the material changed recently? Has a new lot been introduced? Has regrind been introduced? Has the melt Index of the material changed? Normally this is not the cause unless many changes have been made. If this is in question, a good place to check would be with incoming receiving. They should have the information needed to evaluate. Has the material feed been interrupted and the machine ran empty? If using a hygroscopic material, has the material had sufficient time to dry at the correct temperature? Hygroscopic materials encapsulate moisture within the pellet. Non-hygroscopic materials collect surface moisture and also need to be dried prior to production. Normally these materials require drying at low temperatures for short amounts of time. By examining the 5 M's, you should be well on your way to identifying the cause of your process defects.  Contact us if you'd like some more recommendations on how to improve your process and reduce your defects. **Ready to reduce your ****production downtime**** to protect your profits? Learn more about how ****purging compounds**** and process efficiency work in tandem.** ![Yoko Tanaka](https://www.asaclean.com/hs-fs/hubfs/Yoko%20Tanaka%20Headshot%203-25-16.jpg?width=150&name=Yoko%20Tanaka%20Headshot%203-25-16.jpg) #### [ Yoko Tanaka ](https://www.asaclean.com/blog/author/yoko-tanaka) Yoko Tanaka is the Marketing Manager at Asaclean. She has been helping molders and extruders learn about Asaclean purging and how to improve their processes for the past eight years. - [Share On LinkedIn ](https://www.linkedin.com/in/yokotanaka/) ## Related Posts [![Injection Molding Defects: Poor Color Dispersion](https://www.asaclean.com/hs-fs/hubfs/AI-Generated%20Media/Images/this%20image%20depicts%20lots%20of%20very%20colorful%20plastic%20pellets-1.jpeg?width=450&height=250&name=this%20image%20depicts%20lots%20of%20very%20colorful%20plastic%20pellets-1.jpeg) Injection Molding Defects: Poor Color Dispersion Troubleshooting / 2 min read / November 20, 2018 ](https://www.asaclean.com/blog/injection-molding-defects-poor-color-dispersion) [![Happy 4th of July from Asaclean.](https://www.asaclean.com/hs-fs/hubfs/AI-Generated%20Media/Images/Can%20you%20show%20a%20fireworks%20display%20behind%20an%20american%20flag.jpeg?width=450&height=250&name=Can%20you%20show%20a%20fireworks%20display%20behind%20an%20american%20flag.jpeg) Happy 4th of July from Asaclean®: Holiday Closure Announcement purging... / 1 min read / June 24, 2025 ](https://www.asaclean.com/blog/happy-4th-of-july-from-asaclean-holiday-closure-announcement) ## Comments Get Started ## Ready to start improving your efficiency and increasing your profitability? - [Request a Consultation](https://www.asaclean.com/blog/the-5-ms-troubleshooting-process-defects#) - [Contact Sales](https://www.asaclean.com/blog/the-5-ms-troubleshooting-process-defects#) ![](https://www.asaclean.com/hubfs/assets/images/icons/icon-layers.svg) #### Free Sample Request a free sample of Asaclean® Purging Compounds for your plant and start saving today. 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[See your savings](https://www.asaclean.com/cost-savings-calculator) [ Back to Top ](https://www.asaclean.com/blog/the-5-ms-troubleshooting-process-defects#top) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Yoko Tanaka", "url" : "https://www.asaclean.com/blog/author/yoko-tanaka" }, "dateModified" : "2025-07-08T16:20:15.170Z", "datePublished" : "2018-04-06T16:41:48.000Z", "headline" : "The 5 M's: Troubleshooting Process Defects", "image" : [ "https://www.asaclean.com/hubfs/AI-Generated%20Media/Images/This%20image%20depicts%20someone%20writing%20the%20word%20DEFECTS%20and%20circling%20it%20with%20a%20red%20marker.jpeg" ], "mainEntityOfPage" : { "@id" : "https://www.asaclean.com/blog/the-5-ms-troubleshooting-process-defects", "@type" : "WebPage" }, "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://www.asaclean.com/hubfs/Asaclean%20Logo%20TM.jpg" }, "name" : "Asahi Kasei Plastics North America" } } ``` ```json { "@context" : "http://schema.org", "@type" : "Article", "articleBody" : "Many times when processes go awry the true cause is not identified. Too often significant changes are made without a just reason behind them, other than the assumption that “I know how to fix that.” Every technician has a silver bullet and they always think it’s a better fix than the one provided by the previous shift. Before making any major changes to your process, you should always consider the 5 M’s.", "author" : { "@type" : "Person", "name" : "Yoko Tanaka" }, "datePublished" : "April 06, 2018", "headline" : "The 5 M's: Troubleshooting Process Defects", "image" : "https://468726.fs1.hubspotusercontent-na1.net/hubfs/468726/AI-Generated%20Media/Images/This%20image%20depicts%20someone%20writing%20the%20word%20DEFECTS%20and%20circling%20it%20with%20a%20red%20marker.jpeg", "name" : "The 5 M's: Troubleshooting Process Defects", "url" : "https://www.asaclean.com/blog/the-5-ms-troubleshooting-process-defects" } ```