INTRODUCTION FOR TECHNICAL TROUBLESHOOTING AND EFFECTIVE REPAIRING FOR MAINTENANCE

Maintenance have moved from backyard support role to the front runner with major role as critical department. More so, modernization have changed the equipment generation to hi-tech and sophisticated. This have changed the prerequisite of current technicians.

Technicians are required to understand problems in-depth and perform repairs at the time possible. In order to do this effectively, the maintenance personnel should be equipped with latest trouble shooting tools. They must understand various techniques and the correct methodology for application. One other important  factor that requires attention is the ability to make correct and good decisions.

This programs covers this critical aspects to enlighten the maintenance personals.

COURSE OBJECTIVE

• Provide in-depth understanding of failures.
• Understand the implication of high down time.
• How PQCDSM is going to be affected.
• Provide latest troubleshooting skills.
• Allow practical time for classroom analysis.
• Simulate failure scenario and show proper approach.

COURSE CONTENT

Module 1.   Prerequisite For Effective Trouble Shooting.

• What Is an Effective Trouble Shooting.
• Why Effective Trouble Shooting.
• 6 Key Prerequisite for Effective Trouble Shooting.
• The Right Mentality for Trouble Shooting.

Module 2.  Troubleshooting & Repair Process.

• What is Trouble Shooting & Repair Process
• The Four Stages in Trouble Shooting and Repair Process.
• Difference Between Down Time and Repair Time.

Module 3.  Troubleshooting Technique –

‘Equip Yourself First’

• Importance Of Good Tools.
• Importance Of Diagnostic Instruments.
• Visual Aids.
• Availability Of Systematic Troubleshooting Guide (STG)
• ‘Think About All Possibilities’

Module 4.  Troubleshooting Techniques –

‘Preliminary Investigation’

• Define What Failure.
• First 3 Key Steps.
• Perform Physical Troubleshooting.
• Assess Your Finding.

Module 5.  Troubleshooting Technique –

‘Analyze The Finding’

• Common Difficulties During Analysis.
• Four Components of a Problem.
• The Why? Why? Analysis.

Module 6.  Troubleshooting Technique –

‘Mentally Programming Possible Cause’

• What is Mental Programming.
• Building a Mental Relationship Diagram.
• Develop an Elimination Methodology.
• Narrow Down the Potential Cause.

Module 7.  Troubleshooting Technique 

‘Determine The Root Cause’

• What is Root Cause Analysis.
• Why Root Cause Analysis.
• Introduction to Fault Tree Analysis (FTA)
• Application of FTA.

Module 8.  Effective Corrective Action

• Common Difficulties During Repair.
• Pay Attention to Safety Requirements.
• “Must Do” During Repair.
• Verify the Cause.

Module 9.  Evaluating Effectiveness of Repair.

• 5 ‘E’ of Quality Repair.
• Perform Test Run.
• Observe Equipment Operation.
• Record All Corrective Actions.
• 5 Min “Lesson from Breakdown”
• Measure Effectiveness of Repair Activity.
• Measure Repair Efficiency Through MTTR.