Logical Troubleshooting p.2
The Work Order - The first step is to understand what the work order (W/O) is asking of you, or in reality, what is the owner of the broken system asking you?
Many times the owner is either clueless or lazy when it comes to filling out the W/O. How many times, the only words on the chit are "broken" or "doesn't work?" Here education is the best tool. If Leadership will support you, then take the W/O back to its originator and say, "When you fill this out correctly, telling me what the perceived issue is, then I'll fix it."
I once received a W/O that said: "Broken. Emits dead-fish odor." This actually sets you in the right direction, but even if it smells funny, what is broken? It won't turn on? It makes a bad grinding noise? The lights in the entire bay dim-out when it's switched on? Anything that will take you off the wild goose chase!
What Do You Know About the Down System? - Do you know how to turn this device ON? Do you know what it is supposed to do, how it functions correctly? Could you operate it in pace of its owner? If you do not have a really good understanding of a particular machine, take someone with you to work. If this is not possible, try to get an idea of what it is doing from the Operator vs.what it should be doing then return to a quiet place with the service manual.
20 Questions to the Operator - Sometimes talking to the Operator can solve the entire problem. Have them walk you through what they did to make them discover a fault. Sometimes they overlook a setting, and going through it with you, do everything right, and Voilà, it works! Close the W/O. If not, the more information you have about the failure, the easier it is to narrow-down the fault.
Check Power and Supply Connections - Whilst you are having the conversation with the Operator, make sure it has a good power-connection and that the gasses, steam, vacuum and any other external requirements are available. Things like raw-materials and supplies count here too. I cannot tell you how many times the lab-instrument was unplugged (behind the device) or the vacuum-line valve was off! Plug it in, turn it on and it works like a charm. It's better to check these things out first than tearing the machine apart only to find it was out of paper!
Check Controls and Set-Ups - Just like power, some machines won't run if the controls or the raw materials are set-up just right. Think in terms of a photocopier or a printer: it takes very little error in alignment of the paper-supply to stop the machine from functioning.
Operator Error? - It is the easiest of fixes, albeit the most embarrassing for the Operator. Better this way than to spend a week only to find the vacuum was turned off!
The other important thing here is educating the Operator; not only will you not waste time ,production won't suffer.
Please Turn the Page>>>
