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Troubleshooting: Identifying Problems 180

Quality Training

Class Information

Tooling U classes are offered at the beginner, intermediate, and advanced levels. The typical class consists of 12 to 25 lessons and typically requires at least two hours of instruction time.

Class Name:	Troubleshooting: Identifying Problems 180
Description:	This class provides an introduction to the troubleshooting process and describes basic steps for identifying problems.
Prerequisites:	none
Difficulty:	Beginner
Number of Lessons:	13

Troubleshooting: Identifying Problems 180

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

Class Objectives

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.

Class Vocabulary
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.