I don't want to sound critical, I didn't realize what a small company it is. That's a lot of GHs to have to put together with just a few employees. No wonder it's so slow - quality control needs to be priority.
It can be a very awkward transition to make. Making 100s is nothing at all like making one, usually, which is why there are traditional steps taken to deal with these very issues (final design, procurement, assembly, test, QC, inventory control and so on), which are sure to 'pop up'. Especially if there is no plan. Murphy is lurking.
I hope for fewer faulty units once they get their crew trained.
Amen to that. But there's a lot of ground to cover yet. Consider right now those few, very overworked guys that are putting in the Hero Time to get units shipped are the exact same resource that is required to TRAIN THAT CREW! They have no time for that even if they do have the skills needed to establish, train, and supervise Production/QC/Inventory Control/Shipping and so on. Issues they are just now confronting. Training workers should have been part of a plan and 'ready to come on line' at the right time. It's part of 'just in time Manufacturing', people are a resource too.
That training should have already been done, the Manufacturing functions defined if not in place. Now they're playing catch up ball with their exhausted first string, already stretched too far who should be doing other things anyway.
But, IMO, that crew (and their support staff) should already have been hired and trained long before now. As is traditional. Trying to 'do it smarter' isn't working out so well?
"The first job you have to delegate is the one you do better than everyone else".
But seriously heat there is a no-no. Probably a short circuit.
Perhaps, but I think it's more likely poor connection? A LOT of power (current wise) goes through that area it seems. Any resistance at all (and there is always some this side of Superconductors) means voltage drops and power developed. This is why you need a thick extension for high power tools, small ones get hot?
I think the dicey connection involved could be internal, but is also likely in the threads. Actual 'atom to atom' contact can be a small fraction of the total cross section. Like loose wires in a car or wall outlet this can cause serious local heating.
I think the solution is in Product Engineering (the way things are designed, the fine points, and how they're built). Some 'DMIs' (Detailed Manufacturing Instructions) might be called for as well as perhaps some dedicated test fixture/routine for 100% testing of the assembly?
Remember them saying over a month ago that things were taking longer than expected, but they were testing every hopper after assembly before shipping out?
Evidently not. Or the PO is opening them and sabotaging them? That can happen if you're not playing by all the rules. It's especially dangerous in Service. While you should never ever have the guys working on it deciding what ships and when (nor as much as possible keeping 'the suits' (sales) out of those decisions) it happens. Without strong structure it can be a very serious danger.
Ideally QC (or more correctly QA) 'should report directly to the Old Man'. Completely separate from Production. And it should include Incoming Inspection as determined. Before production parts are bought, 'they' should be there. A 'cart before the horse' kinda thing?
Hopefully they're continuing to solve these (IMO to be expected) issues. They've come a long way. Their real job is to make a set of instructions for 'anyone' to build GHs from. Only 'paper', with maybe an example or two. A complete package that 'any factory' (with their established trained workers, Inventory Control, Inspectors, Supervisors and so on) could 'bang out' in whatever volume/schedule needed.
No formal "Production Release" of the package yet.......IMO serious mistake. Even if informal, that's a critical function. They should have defined the steps and been 'ticking them off' to identify where work needed to be done. And when the job of Design was over and Production started. Or so I was taught.
They've come a long way, I'm sure the desire to overcome and finish the job is strong. They just need to feel it out.
And we need to wait for that?
OF