Troubleshooting: Identifying Problems 180

This class provides an introduction to the troubleshooting process and describes basic steps for identifying problems.

Class Details

Class Name:
Troubleshooting: Identifying Problems 180
This class provides an introduction to the troubleshooting process and describes basic steps for identifying problems.
Number of Lessons:
Additional Language:
Related 2.0 Class:
Troubleshooting 181

Class Outline

  • Objectives
  • What Is Troubleshooting?
  • Forming a Problem-Solving Team
  • Deviations vs. Problems
  • Everything Is a Process
  • Examining Process Steps
  • Using Specifics to Identify Problems
  • The Importance of Documentation
  • The Impact of Cost
  • Prioritizing Problems
  • Signs of Problems
  • Reactive, Preventive, and Predictive Maintenance
  • Summary


  • Describe troubleshooting.
  • Describe the responsibilities of the person in charge (PIC).
  • Distinguish between a deviation and a problem.
  • Describe the role of processes in manufacturing.
  • Describe the practice of examining process steps.
  • Describe techniques for identifying problems with specifics.
  • Describe how documentation is used in troubleshooting.
  • Describe the impact of cost on the troubleshooting process.
  • Identify factors involved in prioritizing problems.
  • Describe the importance of recognizing signs of problems.
  • Distinguish between reactive, preventive, and predictive maintenance.

Job Roles


  • MSSC Quality Practices and Measurement


Vocabulary Term Definition
black box A term used to describe the part of a process that is not completely known or understood. The internal workings of a machine could be considered a black box by the operator.
cost The total monetary amount incurred during all steps of a process, including expenses such as labor, materials, or energy. Cost can be used to prioritize problems in the troubleshooting process.
deviation A situation that is less than ideal but is temporarily acceptable. A half-filled lubricant reservoir is an example of a deviation.
downtime Unproductive blocks of time during which machine operations cease, often due to mechanical problems.
fishbone diagram A troubleshooting tool that can be used to visually diagram the causes and effects of a problem.
input A step or change that enters and contributes to a process.
output The result of a process, such as a finished part.
person in charge The employee responsible for heading the troubleshooting process and documenting the problem. The person in charge is also known as the "PIC."
predictive maintenance PdM. A maintenance approach that involves testing and monitoring machines in order to predict machine failures.
preventive maintenance PM. Maintenance performed while a machine is in working order to keep it from breaking down.
problem A situation that is unacceptable and must be corrected, in many cases as soon as possible. A machine that is malfunctioning and unsafe is an example of a problem.
profit The total monetary amount remaining when costs are deducted from revenue. Maximizing profit is a goal of all manufacturing facilities.
reactive maintenance RM. Maintenance performed only after a machine fails or experiences problems.
revenue The total monetary amount that a company receives, from sales or other operations. Revenue minus cost equals profit.
root cause The origin of the problem. Troubleshooting attempts to identify the root cause of a problem rather than simply addressing the symptoms.
troubleshooting A systematic approach to solving problems quickly and efficiently.
vibration analysis A PdM technique that uses instruments to monitor and analyze machine vibration to determine if the machine is working properly. Vibration analysis is one of the most common techniques used in PdM.