Course Description

This course provides a systematic approach to troubleshooting for maintenance technicians at any experience level. Participants will learn to analyze their equipment by first sketching maps of the process, systems, and physical equipment layouts as well as learning to use their existing schematics. They will learn to measure and record the equipment settings during normal operation including inputs and outputs. Once the normal operation of the machine is mapped and understood, troubleshooting any issue becomes easier.

By incorporating tools such as troubleshooting matrices, systems and process tables, and analysis-before-action plans, the participants will be able to choose the fastest way to find root cause of the issue and prevent future occurrences of the problem.

Course Length

16 hours

Class Size

Maximum 8 participants

Prerequisites

This class is recommended for those actively employed as Maintenance Personnel.

Instructional Methods

Methods: Class room discussion and “hands on” application using sample documentation provided by Client Oranization. Participants will provide existing or previous maintenance issues for use during troubleshooting exercises.

Exams/Quizzes: Pre/Post Test, In-class exercises, simulations and demonstration of skills during “real time” application.

Outline

Day 1

• Introduction, Course Overview and Objectives
• Basic Troubleshooting Methodology
• Documenting Normal Systems Operation
  • Evaluate existing machine schematics and vendor documentation
  • Building a process sketch; analyze processes by showing the functions of components
  • Building a systems sketch; isolate systems to simplify troubleshooting
  • Physical layout sketch; drawings that identify and locate physical critical parts
  • Identify inputs and outputs; analyze step by step operations
  • Document and record readings and settings while the machine is operating properly
  • Organize information needed for troubleshooting
• Troubleshooting Methodology
  • Define the problem
  • Collect information regarding the problem
  • Analyze the problem
  • Determine sufficiency of information
  • Propose a solution
  • Test the solution
• Troubleshooting Exercise

Day 2:

• Troubleshooting Methodology continued
  • Using troubleshooting matrices
  • Troubleshooting Matrix Exercise
• Hands on Activities
• Group Troubleshooting Activity
  • Participants will be asked to bring problems on their own equipment
  • Group members work together to document and troubleshoot the issue using methods presented during the workshop.
• Wrap-Up

Objectives

At the conclusion of this workshop participants will be able to:

• Analyze equipment by sketching maps of the process, systems and physical equipment layouts
• Use existing machine schematics
• Measure and record the equipment settings during normal operations
• Choose the fastest way to find the root cause by using troubleshooting matrices, systems and process tables, and analysis-before-action plans