3E

Troubleshooting, A Wise Investment of Time         By Russ Bishop

It used to be that when someone let the smoke out of a motor, it was sent to the shop, repaired and returned. If the repair did not solve the problem, there was time to send in the shop “troubleshooter” to figure out the real problem.

In today’s market, equipment breakdowns, associated downtime and subsequent repairs can be very costly to a business. It is vital that the origin of the problem be accurately defined and the proper repairs made in order to get the equipment back in service as quickly as possible. A misdiagnosis of the failed equipment can result in the purchase or repair of the wrong apparatus thus compounding the problem with additional downtime and expense. 

This is where troubleshooting comes in. Troubleshooting is a form of problem-solving used to determine what components are bad, why the components failed, and what it will to take to get the machinery back in operation. Those charged with troubleshooting the breakdown also play a key role in decision making by providing management with a quick and accurate account of the problem and what it will take to get back in service. A troubleshooter has two major tasks: (1) troubleshooting the machinery (2) providing management with an accurate assessment of the problem.                                                                                        

A good troubleshooter is a jack-of-all-trades. They must have good electrical, electronic, and mechanical skills. It also helps to have good people skills and the ability to think clearly under pressure as breakdowns are often stressful situations. It can be difficult to concentrate on solving the problem while fielding questions from excited onlookers who want to know when it will be fixed and what it’s going to cost. 

Troubleshooting is a mind set

Troubleshooting often starts by looking for the simplest possible cause of the problem. The first question in a troubleshooting guide for an appliance might be “is it plugged in”.  Complex systems can include motors, controls, transformers, drive, and driven apparatus. Problems can arise with any one or a combination of components in the system.  

Troubleshooting complex systems is often a process of elimination by checking each component one by one or substituting known good components for suspect components. It is important to make only one change at a time, and then do a test and note the result. Keeping good notes and not jumping to conclusions too soon is imperative.  Interviewing the operator or person most familiar with the “sound, feel, and operation” of the machine can provide valuable clues. Ask about recent changes; what else is different or does not work; did the machine recently sound different or vibrate; recent repairs or upgrades. Chronic problems due to poor application, design or installation are tough to solve. Electric motors and electronic apparatus are very susceptible to damage from misapplication. It is not surprising to hear of machinery that has had chronic breakdowns for years due to misapplication or poor design. The maintenance department gets so used to making routine repairs and never stop to question WHY the machine is always breaking down.

Solving these problems often starts with taking time to examine the failed components and re-check engineering. Troubleshooting “people problems” is another challenge. If others have attempted to fix the problem, the troubleshooter must now determine if it’s broken……or did someone mess it up. The latter can be a nightmare if that person did not track changes, keep notes or mark connections correctly. A troubleshooter must then reorganize the machine before beginning repairs.  Solving problems with obsolete or foreign apparatus can be very difficult, especially if there is no factory support or schematic. In such cases knowing when to quit is important. An upgrade to a replacement or the appropriate product could be quicker and less expensive in the long run.  If you’re stuck get a second opinion. It helps to talk with someone else about the situation.   

The Troubleshooting process is not complete until the repaired or replaced components are tested upon startup. It is important to make sure your initial diagnosis was correct. Check for things like excess vibration, proper alignment and/or belt tension, etc. Make sure amperages are within the rating of the apparatus.  Quick fixes (temporary repairs) are often necessary; however they can lead to disasters if the quick fix is the only fix. It is important to plan to return and make the appropriate repair when time allows, even if it means stockpiling production or scheduling repairs after hours.  

Employers!

Knowledge is power. Take advantage of technical schools and seminars for those in your employ charged with troubleshooting. The right test equipment is also important. Having the appropriate test equipment on hand can pay for itself after one breakdown. A good troubleshooter is invaluable to your business. Give your troubleshooters assistance and space to solve problems.   Safety is paramount to the troubleshooting process. People naturally get in a hurry in a breakdown situation so it is important to have the appropriate safety gear and follow outlined procedures to avoid personal injury. Troubleshooting means taking the time to accurately diagnose a problem before beginning repairs, which in the end equals saving a lot of time (and money) for everyone involved. 

Last Updated ( Monday, 03 December 2007 )