Efficient troubleshooting minimizes downtime and disruption in the production workflow. It is critical to understand best practices for seamlessly troubleshooting equipment. Alpine® Equipment Support utilizes a six-step process for troubleshooting that helps find and fix problems faster, reduces downtime, tracks reoccurring problems, and reduces labor.
1. Problem Identification
The initial “problem” detected is likely a symptom of the root cause. Start by asking key questions to identify the cause—did the problem show up during start up? Was there a crash/damage to the equipment before the problem? How did PM or service part replacement work prior to the problem? Try to focus on one problem at a time, starting with the biggest pain point and working on it until it is resolved. Then, proceed with the next problem. Solving the root cause may resolve all the associated problems/symptoms.
2. Establish a Theory of Probable Cause
Document the list of possible causes and categorize it from highest to lowest probability.
3. Establish a Plan of Action
Based on the list of probable causes, create and document an action plan. Determine if different personnel and/or tools are needed and are available to help troubleshoot. Try to avoid incorporating used parts (or new parts from a new source) into the equipment while troubleshooting, which may create unexpected results. If possible, it’s always best when replacing parts to use established parts versus new suspect parts (e.g., new manufacturers).
4. Implement the Plan
It’s go time! It is critical to make only one change at a time and test the results after each change. Making more than one change at a time may cause unexpected results, more time back tracking, and unnecessarily replacing good, working parts. If an unexpected result occurs, reverse the steps. Installing untested used or repaired parts may also cause issues. We strongly encourage testing any used or repaired parts (and tagging with test date and results) prior to stocking in spare parts inventory.
5. Verify Full Functionality
Once the initial problem is solved, all aspects of the equipment operation need to be tested to validate that no new or different problems were introduced during troubleshooting. The troubleshooting steps might have to be reversed if a new problem is introduced. The new problem will need to be reviewed first before making the decision to reverse work that was already completed. If everything is operational, review the work performed and clean up or finish installing what was replaced in Step #4.
6. Document Findings, Actions, and Outcomes
Creating an accessible knowledge base is extremely important. Document the findings, actions, and outcomes to ensure easy access for anyone needing the information. Documenting significantly reduces any future downtime, resulting in less disruption to the production workflow. Alpine encourages a proactive strategy for equipment support by utilizing on-line training content (webinars), technical support (phone) and on-site services. Contact Alpine® Support to learn more about our services: machinerysupport@alpineitw.com.