Today’s production plant and equipment is a hybrid ‘engineering system’ comprised of mechanical, electrical/electronic and PLC controller functions. The faults that lead to breakdowns can be in any part of these systems. As a result the time taken by maintenance engineers to locate and diagnose these faults has been increasing. Coupled to this is the need to drive down operating costs to remain competitive in the market. This has led to most companies implementing change programmes aimed at creating a more flexible workforce (multi-skilling).
A particular skill that is often overlooked in these programmes is that of ‘Fault Finding’. It is only when the fault has been found (and the underlying cause diagnosed) can the multi-skilled engineer utilise his new skills and affect a repair. Even then the return in multiskills training is often not fully realised because of failure to identify and remove the cause.
• Develop the ability to THINK LOGICALLY.
• Encourage the adoption of a systematic and methodical approach to faultfinding.
• Adopt a ‘systems’ approach when working on modern hybrid plant and equipment.
• Understand the need for and benefits of good diagnostic aids.
• Understand and use a range of fault finding techniques
E.g. Six Step Approach, Half-split Technique, etc.
This course is based on a realistic engineering system incorporating the Siemens S7 PLC. The understanding of how the PLC functions within the overall system forces trainees to ‘think logically’ and adopt a systematic and structured approach to fault finding during the ‘hands-on’ exercises embodied in this course.
Trainees quickly learn that old methods of taking an ‘ad-hoc’ approach to faultfinding only results in increased stress levels and very often failure to find and rectify faults – even when such faults are extremely simple being anything from power failure, short circuits in wiring, mechanical failure of component parts or more complex PLC / computer /software faults.
The course can be tailored to individual company’s needs incorporating their own documentation e.g.. schematics, ladder diagrams, circuit diagrams.
1. Introduction to course objectives and establishing the need for a logical and structured approach to faultfinding.
2. Revision / re-familiarisation of:
• Relay logic and program design
• The Siemens S7 program editor and bit instructions
• Compiling simple programs to run variety of sequences on MTS engineering system simulator.
3. Faultfinding complex engineering systems
• Understanding relationship between:
• Systematic and methodical approach to faultfinding
4. Practical exercises on MTS engineering systems simulators.
• Gathering evidence.
• Finding the fault.
• Identifing and removing the cause.
5. Using diagnostic aids to rapidly locate and diagnose faults
• Fault/Symptom Analysis Charts.
• Functional Block Diagrams
6. Practical exercise in drawing functional block diagrams.
7. Techniques used in logical faultfinding
• The ‘Six Step Approach’
• The ‘Half Split’ Technique
8. Practical exercises to develop a systematic approach.
9. Principles of good communications when gathering evidence in Step 1.of ‘Six
10. Summary and review of learning outcomes.
Who should attend
Maintenance engineers, supervisors and managers who have
a responsibility basic to reduce downtime.