Last updated on Aug 7, 2024

You're facing complex industrial machinery failures. How do you adjust your troubleshooting strategies?

When you're up against complex industrial machinery failures, it can feel like a high-stakes puzzle. Each piece of the machine is integral to its overall function, and when one fails, it can have a cascading effect. As a field service engineer, you need to approach these failures with a strategic mindset, adapting your troubleshooting methods to the complexity at hand. Your ability to diagnose and resolve these issues not only restores operations but also safeguards the longevity of the machinery and the safety of its operators.

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1 Initial Assessment

Before diving into the machinery's intricacies, you must conduct a thorough initial assessment. Gather as much information as possible about the symptoms and conditions leading up to the failure. Speak with the operators to understand the events preceding the malfunction. Examine maintenance records and logs for any anomalies or recurring issues. This foundational step helps you form a clear picture of the problem, which is crucial for effective troubleshooting.

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William Dukes

Medical Maintenance Chief
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I've always found it helpful when conducting an initial assessment to research the work order history to find out if this is a continuous failure or when the last preventative maintenance inspection occurred to determine if the equipment has a repeat issue or if it could be maintenance indicuced. There are also environmental factors such if there where power outages that may affect the function of the equipment. It is helpful to treat the initial inspection as an investigation of sorts.

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2 Safety Protocols

Safety must be your top priority when dealing with industrial machinery. Ensure that all necessary safety measures are in place before you begin any hands-on work. Lockout-Tagout (LOTO) procedures should be strictly followed to prevent accidental energization of the machinery. By adhering to safety protocols, you protect not only yourself but also anyone else who may be present in the vicinity of the equipment.

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William Dukes

Medical Maintenance Chief
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It is also helpful to create a binder with standard operating procedures when performing lock out tag out procedures. Creating a step by step process with a log of equipment that is currently under lock out tag out is also advisable. This creates a standard for the organization for all team members to follow.

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3 Technical Documentation

Consult the machine's technical documentation, such as schematics, blueprints, and manuals. These resources provide invaluable insights into the design and function of the machinery. Understanding how the system is supposed to operate will help you pinpoint where the failure might have occurred. Familiarize yourself with the normal operating parameters so that you can quickly identify any deviations that may be contributing to the malfunction.

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William Dukes

Medical Maintenance Chief
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Attending user level training for the equipment you will be maintaining is a great way to familiarize yourself with normal operationing conditions. This creates perspective of normal operation procedures which may come in handy when troubleshooting.

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4 Diagnostic Tools

Leverage advanced diagnostic tools to gain a deeper understanding of the issue. Use multimeters, oscilloscopes, and specialized software to monitor the machinery's electrical and mechanical performance. These tools can help you isolate faulty components by measuring voltage, current, resistance, and other critical parameters. Accurate diagnostics are essential for resolving complex failures efficiently.

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William Dukes

Medical Maintenance Chief
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It is important to maintain all diagnostic equipment on a regular calibration cycle. This ensures that your test equipment is accurate as possible.

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5 Root Cause Analysis

Perform a root cause analysis (RCA) to identify the underlying reasons for the failure. This systematic approach involves examining the failure in detail to determine why it occurred and how it can be prevented in the future. By identifying the root cause, you can implement a more permanent solution rather than just a temporary fix. This not only resolves the current issue but also enhances the reliability of the machinery.

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6 Continuous Learning

The field of industrial machinery is ever-evolving, with new technologies and methods constantly emerging. Stay abreast of the latest advancements in your field by engaging in continuous learning. Attend workshops, seminars, and training sessions to sharpen your skills and expand your knowledge base. This commitment to professional growth will enable you to tackle even the most complex machinery failures with confidence and expertise.

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You're facing complex industrial machinery failures. How do you adjust your troubleshooting strategies?

1

2

3

4

5

6

1 Initial Assessment

2 Safety Protocols

3 Technical Documentation

4 Diagnostic Tools

5 Root Cause Analysis

6 Continuous Learning

Field Service Engineering

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You're facing complex industrial machinery failures. How do you adjust your troubleshooting strategies?

1

2

3

4

5

6

1 Initial Assessment

2 Safety Protocols

3 Technical Documentation

4 Diagnostic Tools

5 Root Cause Analysis

6 Continuous Learning

Field Service Engineering

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