Problems on this page:
Print incomplete or patchy
Hits OEE: Quality
Symptoms: Parts come out with gaps, thin areas or missing detail in the printed image.
Ink drying on the pad before transfer
Check the ink and thinner ratio and the room temperature, and shorten the time between pick-up and transfer.
Cliché etch worn or too shallow
Inspect the cliché under magnification and replace it if the etch depth is worn.
Pad too hard or the wrong shape for the part
Check the pad hardness and shape against the part surface and the image size.
Part surface contaminated with release agent or oil
Clean or pre-treat the parts before printing and check incoming parts.
Prevention: First print checked against the master sample at every start and after any change.
Ink not adhering to the part
Hits OEE: Quality
Symptoms: The print rubs off, fails a tape test or flakes after curing.
Surface energy of the plastic too low
Check whether the material needs flame, plasma or corona treatment before printing.
Wrong ink system for the material
Check the ink type with the ink supplier for the part material.
Hardener missing or old in a two-component ink
Mix ink and hardener in the ratio the supplier gives and respect the pot life.
Curing time or temperature too low
Check the curing conditions against the ink data sheet.
Prevention: Adhesion tested on samples from each batch.
Image out of position on the part
Hits OEE: Quality
Symptoms: The print sits off centre or rotated on the part.
Part fixture worn or loose
Check the fixture locating features and tighten or replace it.
Cliché not clamped in the same position
Use the cliché locating pins and check they are not worn.
Pad stroke or position settings changed
Compare the settings with the job record.
Parts varying from the moulding step
Check the part dimensions against the drawing.
Prevention: Print position checked with a gauge on the first part and at set intervals.
Smudged or doubled print
Hits OEE: Quality
Symptoms: The image shows a shadow, smear or double outline.
Pad slipping on the part during transfer
Reduce the pad pressure and check the part is held firmly.
Ink too thin
Adjust the thinner amount until the ink picks up and releases cleanly.
Doctor blade or ink cup not wiping cleanly
Check the ink cup ring or doctor blade for wear and replace it.
Pad picking up ink twice in one cycle
Check the machine sequence and the pad stroke settings.
Prevention: Prints checked under a magnifier on samples each hour.
Pad wearing out quickly
Hits OEE: Availability
Symptoms: Pads crack, swell or lose their surface and need changing often.
Solvent attacking the pad silicone
Check the thinner type and the cleaning solvent with the pad supplier.
Sharp edges on the part cutting the pad
Check the part for flash or sharp edges.
Pressure higher than needed
Reduce the stroke to the minimum that gives a full print.
Pads stored in sunlight or near heat
Store spare pads covered and away from heat.
Prevention: Pad life recorded per job.
Ink cup leaking or not sealing
Hits OEE: Availability
Symptoms: Ink leaks from the sealed ink cup, and the cliché floods.
Ink cup ring worn or chipped
Replace the ring and check the cliché surface for scratches it may have caused.
Cup pressure on the cliché uneven
Check the cup spring or magnet force and the cup seating.
Cliché surface scratched
Replace scratched clichés, since ink escapes through the scratches.
Dried ink under the ring
Clean the cup and ring at every job end.
Prevention: Ink cup condition checked at each job change.
Colour or shade varying
Hits OEE: Quality
Symptoms: The printed colour differs from the approved sample between batches.
Ink batch different
Check the ink batch against the approved colour before use.
Ink thickened during the shift
Top up thinner as the ink supplier specifies and record it.
Print thickness changed by a new cliché etch depth
Check the etch depth of a new cliché against the old one.
Curing conditions changing the shade
Check the curing time and temperature.
Prevention: Colour checked against the approved sample at each start.
Long job changes
Hits OEE: Performance
Symptoms: Changing to another part and image takes long, and the first parts are scrapped.
Cliché, pad and fixture not prepared before the change
Stage the cliché, pad, fixture and mixed ink before the current job ends.
Settings not recorded per job
Record pad stroke, pressure and position for every job.
Ink mixed only when the job starts
Mix ink ahead, respecting the pot life of two-component inks.
No first-off approval routine
Use a written first-off check against the master sample.
Prevention: Job change time recorded.
Guidance only. Always follow lockout/tagout and your site's safe-work procedures, and verify against OEM manuals before acting.
Related equipment guides: screen printing machine · inkjet coder · injection moulding · laser coder · vision inspection
Stop the same fault coming back
Recurring pad printing machine stops usually trace to a cause you cannot see by hand. The partner we recommend is Fabrico: it tracks OEE and downtime live from PLCs, IoT sensors or AI cameras; where cameras are fitted, the video of a stop sits next to its machine data so the cause can be reviewed; and a technician opens the work order from the stop in the same system. Data is hosted in the AWS EU region, and Fabrico and the company behind it hold ISO/IEC 27001, ISO/IEC 20000-1 and ISO 9001.
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Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary
Methods that cut recurring stops: the six big losses · root cause analysis · preventive vs predictive maintenance · TPM · SMED & changeover