Basictroubleshooting

BASIC TROUBLESHOOTING
STRATEGY
DEVELOPING A
FUNCTIONAL SEARCH STRATEGY FOR AN
EFFECTIVE BASIC
TROUBLESHOOTING PROCESS
Edited from Bob Lonzo Presentation
COURSE OVERVIEW
Course Objectives
What is troubleshooting?
Troubleshooter Styles
Basic Troubleshooting
Search Strategy
Using the Troubleshooting Tools
Review and Evaluation
COURSE OBJECTIVES
This course is designed to present to
the participant a Basic Troubleshooting
Search Strategy that can be used to
troubleshoot and identify malfunctions
in any type of industrial process
environment.
COURSE OBJECTIVES
Upon completion of this course, the participants
will be able to;
Apply basic troubleshooting search strategies to several
different process problem scenarios and effectively
identify a malfunction.
Identify the components and documentation
associated with troubleshooting plant floor systems
and their work areas.
Use the identified components and documentation
to identify the root cause of a malfunction.
COURSE OBJECTIVES
Upon completion of this course
the participant will be able to:
Identify the various troubleshooting
styles and list the advantages and
disadvantages for each.
List the elements in the Basic
Troubleshooting Strategy.
Demonstrate the how to utilize
machine HMI screen to obtain data.
COURSE OBJECTIVES
WD machine drawings
to obtain data.
control system indicators
to obtain data.

machine manuals to obtain data.
Prepare a maintenance repair

document for use in their
daily activities.
TROUBLESHOOTING DEFINED
The Definition of TROUBLESHOOTING is
To operate or serve as a troubleshooter
TROUBLESHOOTING DEFINED
The Definition TROUBLESHOOTER is;
A person skilled at solving or

anticipating problems or difficulties.
A skilled worker employed to locate

trouble and make repairs in machinery
and technical equipment.
An expert in resolving diplomatic or

political disputes a mediator of
disputes that are at an impasse.
TROUBLESHOOTING STYLES
GAMBLERS
TESTERS
THINKERS
GAMBLERS
WANDERERS
RISK TAKERS
ODDSMAKERS
SWAPPERS
WANDERER
Relies completely on random chance to

find the problem!
Logical sequence not followed!
Requires little knowledge of

troubleshooting strategy!
Forgets what already has been tested!
Tends to waste time and effort!
WANDERER
Conducts exhaustive search by checking

everything in the system!
Gets lost in the search!
Lack schematic interpretation and

component diagnostic skills!
Limited system understanding!
RISK TAKERS
Reconfigures the system to
provide new information!
Very dangerous to both
equipment and personnel!
Likes to experiment with
components within a system!
Must use extreme care not to
introduce new faults!
ODDSMAKERS
Rely on knowledge of
common fault occurrences!
Bet on what they think is the

correct solution based on
symptoms they recognize!
Troubleshooting requires an
increasing level of skill!
Quickly become Wanderers!

SWAPPER
Most encouraged form of gambling!
Can be very efficient!
Can quickly get the equipment

functioning!
Exhibits risk-taking behavior!
SWAPPER
Can damage good parts!
Limited to supply of spare parts!
Limited to easily substituted or

modular parts!
TESTERS
SENSORS
TRACERS
SPLITTERS
SENSORS
Likes to look, listen, touch, and smell!
Valuable strategy for obtaining important
information!
Rarely a stand-alone problem
solving method!
TRACERS
Generally use
schematics/prints!
Performs voltage checks,
continuity
checks, or signal tracing!
Start at a known good point in
the
system and work toward the
fault!
TRACERS
Start from a faulty symptom
and
search backward to the
errors
source!
Depends heavily on good test
equipment and
schematic/print
reading skills!
SPLITTERS
Divide & Conquer!
Half split method!
Successive approximation!
Divide a system or circuit in half
and check for proper readings,
then continue to divide and check!
Use jumper wires
SPLITTERS
Disconnect portions of a system
or circuit!
May contribute to confusion
because of the induced interaction
of components!
Potential for damage to equipment
or injury to personnel!
THINKERS
READERS
RECALLERS
DESIGNERS
ANALYZERS
READER
Least skilled form of the
Thinking approach!
Highly recommended in many
situations!
Instances still arise to
troubleshoot manually!
Must be able to switch to
another style of troubleshooting!
RECALLERS
Rely more on their memory of
symptoms and solutions from
many years of experience!
Troubleshooting needs continual
practice!
Tend to lose troubleshooting skills!
Solve common problems in familiar
systems!
DESIGNERS
Use theoretical knowledge to
evaluate faults!
Rarely efficient!
ANALYZERS
Highly skilled troubleshooters!
Use system knowledge and
observations (sight) of symptoms
to eliminate portions of a system
in a logical way!
ANALYZERS
Requires a detailed understanding
of the system!
Think before you approach!
Relies on
FUNCTIONAL SEARCH STRATEGIES
What is your Troubleshooting style?
GAMBLER
Wanderer, Risk Taker,
Oddsmaker, Swapper
TESTER
Sensor, Tracer, splitter
THINKER
Reader, Re-caller,
Designer, Analyzer
List any advantages to being a SWAPPER.
List the disadvantage to being a SPLITTER.
Of all of the Troubleshooting
Styles presented, which Style
is the least efficient?
Which Style is most efficient?
THE BASIC TROUBLESHOOTING STRATEGY

SENSORY INPUT
FILTERING
FILTER THE FILTER
ACTION
RE-ACTION
NO
YES
DOCUMENTATION
PROBLEM
SOLVED
REPAIR

SENSORY INPUT
Comprehension of the elements of observation
FILTERING
Skill set for determining root cause of problems
ACTION
Introduction to elements of hardware/software/documentation
to implement root cause analysis

REPAIR
Show examples of necessary items
and information needed to affect repair
DOCUMENTATION
Importance of documenting repairs

SENSORY INPUT
What is Sensory Input?
Using your senses to gather data on the
problem.
Every malfunction leaves certain clues
as to where the problem occurred and what
is needed to start the troubleshooting
process.
The more adept a you are at recognizing
the clues, the more information you will
have to accurately determine root cause

SENSORY INPUT
Examples of sensory input:
Visual Inspection of Machine
Reference HMI device
Listening to the Operator
Checking Visual Indicators on
Modules and Components

SENSORY INPUT
How do you Improve Sensory Acuity?
How does any brilliant idea ever come to
people?
A person takes something he already
knows and thinks about it in a different
way.
Questions like What if- and Imagine if
spark different avenues of thought.

SENSORY INPUT
When is the best time to do troubleshooting
on a machine?
When it is operating correctly.
What if you could see the machine from
a slightly different perspective every
time you look or listen or smell it?
How much intuitive knowledge would you
have about its processes or its sequencing?

FILTERING
Root Cause Concept
Filtering through the different
sensory input should give you a
prioritized list of possible root
causes.
This process is done mentally with
deduction or, sometimes,
induction.

FILTERING
Root Cause Concept
Assumption is the enemy of deduction.
Sometimes, problems that occur may
have the same symptoms but be an
entirely different cause.
How many times have you found
yourself inventing obscure reasons
to justify a cause that you just
KNOW it has to be and find that it was
Something else entirely?

FILTERING
As you learn and gain
experience from a certain
machine line, your filtering
becomes more acute and
your first root cause
possibility will tend to be
the right one.

ACTION
From Thought to Action
After a likely root cause is formulated,
some type of action will be required
to prove the supposition out.
We will make suggestions of the actions
that need to be taken to trace, diagnose,
and/or reference information in the
Control system.

ACTION
Examples of typical action skills are:
PLC Logic Tracing
Searching and Cross-Referencing

Referencing WD Prints
Physical Inspection of Machine
Components
Trend Data Monitoring

FILTERING THE FILTER
The Other Root Cause
Sometimes, first impressions
can be incorrect.
If root cause is not found from
the current action, the subsequent
possibilities must be explored until
a root cause is found.

FURTHER ACTION
Re-Action on the Filter
After an alternate root cause is
determined, all steps listed in the
ACTION step listed above can be
re-used to prove out a possible
root cause.

REPAIR
FIX IT!!!
Once a definite root cause is
discovered, steps need to be
taken to temporarily or
permanently repair the machine.
WD prints can be re-referenced
to locate specific sensors or valves.

DOCUMENTATION
Words for the Ages
Something often overlooked in the
troubleshooting process is
documentation.
Not only does this help other personnel
who may also be troubleshooting that
piece of equipment, it will also help YOU
when two years have gone by and you
completely forget about a problem.

The Basic Troubleshooting Strategy will:
Make your troubleshooting more
effective.
Eliminate duplicate troubleshooting
(Same problem appearing on different
shifts)
Reduce Downtime due to more effective
repair of malfunctions.

List three examples of Sensory Input
Filtering input is a way for you to
discover the _______ _______
of the problem.
What is the final step in the Basic
Troubleshooting Strategy?
THE BASIC TROUBLESHOOTING TOOLS

DRAWINGS
The work area drawing depicts a dedicated area
of the plant comprised of;
machinery
control equipment
personnel
This area implements
the manufacturing
process of a specific
Component(s)

DRAWINGS
Depending on the process, this
machinery may consist of
various pieces of
equipment.
Each executes a
programmed sequence
of operation that puts
the part(s) through various
stages of the production
Process.

DRAWINGS
Area Drawings can be
used to Locate equipment
and controls.
Suggestions;
Make notes on drawings
for reference.
Identify control device
locations

DRAWINGS
Drawings can also indicate the
various control devices,
associated sensor devices,
and their tag names.
These tag names can be
searched and cross referenced
in the working drawings,
tag database, the ladder logic,
and the HMI I/O status display.

DRAWINGS
Device Drawings can provide
The following data;
Tag Name
Node Address
Wire Labels / Numbers
Contact Data (NO or NC)

SEQUENCE OF OPERATION
Details the sequence of a
given machine or process.
Can be used to identify the
area of malfunction.
Problem is usually in the step
just before the uncompleted
step.
Station 25W Widget Assembler
Operator places Widget Part W21 on conveyor
Widget Part W21 moves into assemble

position, pin clamps open.
Widget Part W21 part present #1 and #2 detected.
Widget Part W24 travels to Assemble position

above Widget Part W21
Pin Clamps close on Robot Widget Part W21
The assemble process starts
The W-frame press starts down over Widget

Part W21 and Widget Part W24
W-Frame (Press) continues down and stops

(dwell time).
The clamps extend.
W-Welder Robot spot welds Widget Part W21 and

Widget Part W24
The W-frame press starts up from Widget Part W21

and Widget Part W24
The clamps retract
Widget Part W-25 ( combined W21 & W24) moves

on to conveyor
Widget Part W-25 clears fixture
Next sequence begins

HMI SCREENS
The Human Machine Interface (HMI)

is used to communicate with the
control system of the machines.

HMI SCREENS
The Human Machine Interface (HMI)

is used to communicate with the
control system of the machines.
HMI devices are used to;
Check the operation status of a
Machine.
Permit operator to modify
operation.
Provide alarms and warnings

HMI SCREENS
Typical HMI Screen
Display a system
status.
A form of this
screen is located
on almost all
machine HMIs.

HMI SCREENS
Displays are
typically color
coded (red and
Green) to indicate
normal or fault /
alarm status.
Notice how the
Man/Auto Ready
indicator shows
Auto not ready,
along with the
system local
message.

HMI SCREENS
An example of an Alarm
Display to view system
faults.
Every message has a
event number that is
related to a Message
Event in the controller
logic.

TRACING LADDER LOGIC
ONLY TRAINED INDIVIDUALS SHOULD

ACCESS THE LADDER LOGIC.
Tracing Ladder logic in the controller
requires specialized training in the
particular software used by the controller
unit.
Possible machine damage and personnel
injury can result from un-authorized
modification to the controller logic.

A trained individual can

use a Controller Work
station or a computer
loaded with specific
software to;
View the ladder logic
program executing in
the controller.
Remote
Run
Modify logic
Override some signals
for diagnostics

An example of a Rung of
Ladder Logic.
An input signal or
output signal can be
viewed in real time by
accessing the ladder
logic of the controller
unit.

Tracing a signal in the

logic requires good
documentation of the
various controller logic
elements.
An input signal or
output signal can be
viewed in real time.
Specific Signals can

be modified (forced) to
aid in diagnostics.

CONTROLLER SYSTEM INDICATORS
Controller Systems
usually have Status
Indicators located on
the Controller and
modules.
Using the indicator
LEDs and the Manufacturer
manual one can get a clue
as to the malfunction

Controller Systems usually have
Status indicators located on the
Controller and modules.
Using the indicator LEDs and the
Manufacturer manual one can
Get a clue as to the malfunction

1756-L55 Controller Module

Status Indicator Descriptions
UN - Indicates mode of operation:
Solid Green Processor is running
(reading inputs, executing logic, and
writing output data to enabled output modules)
Off Processor is not controlling outputs
(processor could be in program mode,
test mode, or no power)
ample :

O - Indicates status of configured input and output

modules communication:
Solid Green Processor is communicating to its
configured input and output modules
Flashing Green One or more, but not all,
configured I/O modules is not communicating
Flashing Red No I/O modules are
communicating or the processor has faulted
Off No configured modules

ORCE - Indicates the presence and status of

forced I/O:
Off No forces exist in controller
Flashing Yellow Forces installed, but not active
Solid Yellow Forces installed and active
S232 Communications activity of serial port

Flashing Green Data is being sent or received
through the serial port
AT Status of memory backup battery:
Solid Red Battery Level low and needs
to be replaced
Off Battery is OK, or no power

K Status of Controller module:

Green Controller is OK
Off No power applied
Flashing Red Minor or major recoverable fault
Solid Red Major non-recoverable controller
fault; must be corrected and reset

MANUFACTURER MANUALS
Equipment manufacturers often

times include a troubleshooting
section in the machine manuals.
Check the manuals for hints on

detecting and preventing
malfunctions

All have different styles.
(See this example) Excellent
source of information specific
to the machine.
Some provide flowchart style data

Others provide error
code data.
(See AB Controller
example)
Use the manuals to
interrupt sensory
data.

MAINTENANCE LOGS
Maintaining accurate records of System performance
parameters of each machine will make problem
Identification and malfunction troubleshooting much easier.
The sooner you identify potential problems will result
reduced downtime.

MAINTENANCE LOGS
Early detection can be achieved by recording a
baseline of selective parameters such as
voltages and average readings for each major device
and periodically checking for deterioration.
The baseline data would ideally be collected at
the installation of the system once all of the bugs
have been worked out. In the event that this data
was not collected at installation time, data
collected when the system is functioning correctly
can be used for the baseline information.

MAINTENANCE LOGS
Once the baseline data is established, periodic

checks of the actual network data can be
compared to the baseline and potential
malfunctions addressed prior to becoming
shutdown situations.
The next slide an example of a Baseline data form.
This is only an example. You may wish to develop
your own based on;
Your experience with the network
Operation of particular systems
Certain types of devices

MAINTENANCE LOGS

Troubleshooting Worksheet
MAINTENANCE LOGS
Fill in the form to help you keep track of your troubleshooting effort.
Exercise #
Check Yes in each box if it applies.
Team #
Start with observation.

Questions
Is power on?
Yes
No
Findings
Is the machine cycling?
Does the cell appear to have stopped mid-cycle?
Is there a fault message on the Bingo board?
Another example of a Log

Notice that this example
Follows the Basic
Troubleshooting Strategy
Sensory Input
Are there any fault lights, a fault message, or horn?
Filter
Is it a hardware fault or operational fault?
Are there any unusual sounds?
Action
Has the operator offered any information?
Are there any other unusual things happening?
Determine where to find the cause. Narrowing your focus.
Questions What area are you going to focus on?
Yes
No
Findings

MAINTENANCE LOGS
REPAIR Fix the problem and verify that it works.

Yes No
Questions
Were you able to fix the problem?
Findings
Is the line now in Automatic and ready to

run?
Basic Troubleshooting
Strategy
Do you feel that the root cause was fixed?
Repair
Documentation
DOCUMENTATION Finishing the effort by documenting your findings for others
Yes No Findings
Questions
Is there a logbook to fill out on this line?
Was it necessary to update files after the
repair?
Were the prints updated and valid?
Did you find logic rungs that should be
commented better?
Adds Section for

your Comments and
suggestions

What would you check to determine
the next step in an operation or process?
What should you check to determine the
Controller Systems is functioning
Correctly?
What would you use to determine if the
malfunction had occurred previously?
What would you put on a Log for the
machine you are responsible to
maintain?
THE BASIC TROUBLESHOOTING

Review
GAMBLERS
Relies completely on random chance to find the problem!

Logical sequence not followed!
Forgets what already has been tested!
Tends to waste time and effort!
Checks everything in the system!
Lack schematic interpretation and component
diagnostic skills!
Reconfigures the system to provide new information!
Very dangerous to both equipment and personnel!
Likes to experiment with components within a system!
Must use extreme care not to introduce new faults!

Review
GAMBLERS
Rely on knowledge of common fault occurrences!

Bet on what they think is the correct solution based
on symptoms they recognize!
Troubleshooting requires an increasing level of skill!
Can be very efficient!
Can quickly get the equipment functioning!
Exhibits risk-taking behavior!

Review
TESTERS
Likes to look, listen, touch, and smell!

Valuable strategy for obtaining important information!
Rarely a stand-alone problem solving method!
Generally use schematics/prints!
Performs voltage checks, continuity checks, or signal tracing!
Start at a known good point in the system and work
toward the fault!
Start from a faulty symptom and search backward to
the errors source!
Depends heavily on good test equipment and
schematic/print reading skills!

Review
TESTERS
Divide & Conquer!

Half split method!
Successive approximation!
Divide a system or circuit in half and check for proper
readings, then continue to divide and check!
Use jumper wires
Disconnect portions of a system or circuit!
May contribute to confusion because of the induced
interaction of components!
Potential for damage to equipment or injury to personnel!

Review
THINKERS
Least skilled form of the Thinking approach!

Highly recommended in many situations!
Instances still arise to troubleshoot manually!
Must be able to switch to another style of troubleshooting!
Rely more on their memory of symptoms and solutions
from many years of experience!
Troubleshooting needs continual practice!
Tend to lose troubleshooting skills!
Solve common problems in familiar systems!

Review
THINKERS
Use theoretical knowledge to evaluate faults!

Rarely efficient!
Highly skilled troubleshooters!
Use system knowledge and observations (sight) of
symptoms to eliminate portions of a system in a logical
way!
Requires a detailed understanding of the system!
Think before you approach!
Relies on FUNCTIONAL SEARCH STRATEGIES

Review
DRAWINGS
The work area drawing depicts a dedicated area
of the plant comprised of; machinery , control equipment,
and Personnel
Area Drawings can be used to Locate equipment and
controls.
Drawings can also indicate the various control devices,
associated sensor devices, and their tag names

Review
SEQUENCE OF OPERATION
Details the sequence of a given machine or process.
Can be used to identify the area of malfunction.
Problem is usually in the step just before the uncompleted
step.

Review
HMI SCREENS
The Human Machine Interface (HMI) is used to
communicate with the control system of the machines.
HMI devices are used to; Check the operation status of a
Machine, Permit operator to modify operation, and
Provide alarms and warnings
Displays are typically color coded (red and Green) to
indicate normal or fault / alarm status.

Review
Trace Ladder Logic
ONLY TRAINED INDIVIDUALS SHOULD ACCESS THE

LADDER LOGIC.
Tracing Ladder logic in the controller requires specialized
training in the particular software used by the controller
unit.
Possible machine damage and personnel injury can result
from un-authorized modification to the controller logic.
Use a Controller Work station or a computer loaded with
specific software to; View the ladder logic program,
modify logic, or Override
some signals for diagnostics

Review

Controller Systems usually have Status indicators located
on the
Controller and modules.
Using the indicator LEDs and the Manufacturer manual
one can
Get a clue as to the malfunction

Review
Equipment manufacturers often times include a
troubleshooting
section in the machine manuals.
Check the manuals for hints on detecting and preventing
malfunctions
Manuals provide error code data.

Conclusion Module One
Using the Basic Troubleshooting Strategy improve

Your troubleshooting ability and result in:
Increased production
Reduced down
Confident Workforce

Conclusion Module One
Thank you for your attention.

Keep this process in mind
during the second Module
When we will address specific
Machines on your plant floor.

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BASIC TROUBLESHOOTING

Edited from Bob Lonzo Presentation

Demonstrate the how to utilize

Prepare a maintenance repair

A person skilled at solving or

A skilled worker employed to locate

An expert in resolving diplomatic or

Relies completely on random chance to

Logical sequence not followed!

Requires little knowledge of

Forgets what already has been tested!

Tends to waste time and effort!

Conducts exhaustive search by checking

Gets lost in the search!

Lack schematic interpretation and

Limited system understanding!

Bet on what they think is the

Quickly become Wanderers!

Most encouraged form of gambling!

Can be very efficient!

Can quickly get the equipment

Exhibits risk-taking behavior!

Can damage good parts!

Limited to supply of spare parts!

Limited to easily substituted or

THE BASIC TROUBLESHOOTING STRATEGY

FILTER THE FILTER

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

PLC Logic Tracing

Searching and Cross-Referencing

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING STRATEGY

THE BASIC TROUBLESHOOTING TOOLS

THE BASIC TROUBLESHOOTING TOOLS

THE BASIC TROUBLESHOOTING TOOLS

THE BASIC TROUBLESHOOTING TOOLS

THE BASIC TROUBLESHOOTING TOOLS

THE BASIC TROUBLESHOOTING TOOLS

Station 25W Widget Assembler

Operator places Widget Part W21 on conveyor

Widget Part W21 moves into assemble

Widget Part W21 part present #1 and #2 detected.

Widget Part W24 travels to Assemble position

Pin Clamps close on Robot Widget Part W21

The assemble process starts

The W-frame press starts down over Widget

W-Frame (Press) continues down and stops

The clamps extend.

W-Welder Robot spot welds Widget Part W21 and

The W-frame press starts up from Widget Part W21