Dealing with a complex machinery breakdown on-site. How can you troubleshoot it without causing disruptions?

Completely agree with initial assessment.While frontline engineers who is working on troubleshooting activities of complex machinery have to look on safety first (be it ensuring safe shutdown of machine and ensuring surrounding is clear) to prevent any type of accidents. Conducting visual inspection plays pivotal role during initial assessment to identify issues like leakages,electro faults,loose components and abnormal smell like burning or short circuit. These will also help troubleshooting is done towards right direction.

1. Identify Critical Equipment 2. Create Redundancy - better to implement during the engineering stage 3. Regular maintenance and inspection 4. Create a preventive maintenance schedule for each piece of equipment 5. Maintain Safety Operating Procedures 6. Train employees on Troubleshooting 7. AMS with OEM 8. Install vibration and temperature monitoring for critical equipment 9. Regularly review and update the preventive maintenance plan

There is already a breakdown so it is already disruptive. Stay calm. First step is to observe. What is the current situation and what is the cause/chain of event leading up to this. Prioritize what you are going to do. First things first. Execute your priorities (@JockoWillink)

Begin with a thorough visual inspection and gather information from operators about the machinery's recent performance and any irregularities.One thing I've found helpful is to conduct a quick interview with the machine operators to understand the symptoms and any recent changes that could have contributed to the breakdown.

Condition monitoring is an important tool to continuously assessing the machine behaviour. Abnormalities to be noted and timely correction is to be done. It will help in ensuring the machine availability

Diagnostic tools keep you aware of the equipment's operability. It is worth remembering that we must maintain regular checks not only on the equipment used daily but also on spare parts so that when they are needed, they are ready in perfect condition.

Utilizing diagnostic tools is essential in pinpointing the exact issue within complex machinery. Depending on the machine, you might use a multimeter to check electrical components, diagnostic software for programmable systems, or pressure gauges for hydraulic systems. These tools provide concrete data that can lead you to the root cause of the breakdown. It's important to be familiar with the range of diagnostic tools available and understand how to interpret their readings correctly.

Implementar un mantenimiento preventivo/predictivo es una herramienta fundamental para evitar las fallas inesperadas en operacion: Tecnicas como Termografias, analisis de vibraciones, tintas penetrantes, inspecciones visuales, pueden advertirnos de una falla inminente.

Use of Historical data on equipment indicators to assess which breakdowns is taking toll or assess what category equipment downtimes(major/minor) Scada is a good source to define your strategy.

Refer to maintenance manuals, schematics, and previous maintenance records to understand the machinery's history and common issues.An example I've seen is using the machinery's service history to identify patterns or recurring issues, which can provide clues for current problems.

This is number 1 included above that I have discussed. Periodic review and update especially when new capital equipment is purchased. Never stop reviewing docs until equipment indicators are stable.

L’utilisation de la documentation est très importante, surtout les retours d’expérience pour accélérer la résolution du problème, La documentation aide aussi a travailler selon la meilleur méthodologie possible,

-Isolate component(s). -Test after isolation in simulated conditional states if possible. -Test equipment function by bypassing potential problem component(s) if feasible and safe. -Component swap test if possible (suspected bad switch, swap with known working one, test) - Document all findings.

Data log monitor is good. Further check equipment assists time and breakdowns and apply good troubleshooting and breakdown analysis. This should eliminate the problem of the machine.

Les tests incrémentiels sont importants pour se focaliser sur la partie qui pose problème sur la machine, mais il n’est pas toujours évidant de les faire parfois il nécessite l’utilisation d’outils de service spécifique au model de la machine.

La consultation du personnel sur place doit être fait dans les préliminaires après la mise en sécurité ensuite il faut diagnostiquer. Un rapport de confiance avec ses collègues permet au dépanneur d être plus efficace. L erreur est souvent humaine et il faut faire comprendre que nous ne sommes pas la pour juger ou blamer mais pour remettre en service le plus rapidement possible.

La communication est très important, surtout s’il y a une modification au niveau la fa?on d’utilisation de la machine en attendant une retour a la voix normal,

Update your documentation based on the doc revision and must be followed across all teams. Enhance service engineering needs tools like Spares algorithm to support predictive maintenance and save time and money for a productive high-volume manufacturing environment. Remember, Zero Breakdown in Between Preventive Maintenance Schedule is the key to avoid manufacturing disruptions.

Después de solucionar la avería, es importante implementar medidas de cuidado y mantenimiento para prevenir futuras averías y prolongar la vida útil de la máquina 1. Realiza mantenimiento preventivo: Establece un programa de mantenimiento q incluya la predicción 2.Capacitación del personal: Asegúrate de que el personal esté capacitado para operar y mantener la máquina correctamente. 3.Documentación: Mantener un registro detallado de las reparaciones, mantenimiento y ajustes para facilitar futuras intervenciones. 4. Llevar a cabo inspecciones regulares 5. Actualizaciones y mejoras: Considerar actualizar o mejorar la máquina para aumentar su eficiencia. 6. Garantizar un almacenamiento adecuado de la maquina