Troubleshooting Training Users

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Do it yourself training course teaches how to troubleshoot machines and processes
and includes a real machine for hands-on practice.

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About this troubleshooting course

How does a MIMIC machine help in learning troubleshooting?

Learning materials included in the troubleshooting course

Instructor On A Disk Package

Troubleshooting course contents

FAQ's (Frequently Asked Questions) about the troubleshooting course

Microcontroller-Based systems details

Circuit Boards and Digital Circuits

Curriculum for
community colleges

Mechatronics for community colleges

Links to information about maintenance and troubleshooting

IDEAS! on training and troubleshooting

About the creators of these courses

Available packages and preview materials

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Qualex Inc. (Div of Kodak) (manufacturers of photo imaging equipment)
To Bob Frye "I cannot tell you how pleased we are with the program. We have put all 40 of our internal people through the course. I have not taught the program myself, but use my own instructors." Steven Miller, Technical Training Manager

Qualex puts people through the program one to three people at a time. People work mostly on their own with the instructor serving to introduce activities and act as mentor. Takes about 3 days total time. They surveyed other courses and were impressed with the quality of Systematic Troubleshooting. They are using the program for developing the skills of field service people.

Associated Hygeinic Products (AHP) "Our plant was set to close down. Our Operations Manager said 'We're going to turn this plant around - and STS is going to do it.' And that's what's happening. Also we've got a document-retrievalsystem and other management initiatives as well as good support from the top down. All that makes a difference. Bill Streib, Training and Information Technology.

"We're putting everyone here including production, maintenance and office departsments through the STS program. It's only been a few months, and already our production and morale are up and our costs are down. It's turned us around." Matt Nelson, Engineering and Plant Management.

Bill: Before they attended a class, a large percentage of the people in the plant were involved in filling this out the TSAG or gathering information about this pinhole problem. This was done before those people had been able to do the training. They were very impressed with the fact that the possible causes would end up with different levels of importance. And so it has generated curiosity and excitement. They’re saying “I gotta learn how to use this more!” And these are going to be the next group that’s coming through. I gotta tell ya, its great when you’re teaching a class, to have really enthusiastic people that can’t wait to learn more.

Matt: The foreman we had before used a program called ATS. Analytical Troubleshooting. The process is fairly similar but its not as detailed. It’s much easier to guide ATS to the answer you want. This (STS) guides you to the correct answer. So people understand the probable causes. And going through that process before, they just have to learn how to use the sheet, and just looking at it they have an idea of how it works.

American Tool Company "Bob, I just wanted to let you know that I conducted the first pilot session on the troubleshooting class. The session went very well in spite of some mistakes that I made in the presentation. The session was 12 hours and since I had the participants apply the process to some of the equipment in the factory we ran out of time. They really benefitted from applying it to our equipment. They couldn't keep their hands off the MIMIC machine, it was driving them crazy because they couldn't figure it out. The problem solving in section 9 was excellent, it put to use everything they had gone through and you could see them light up as they finally saw how it all fits together. One reply from a participant, was that he had been to a lot of troubleshooting classes and this was the best he had ever seen. That made me feel pretty good and hopefully it does you as well."
James Reed, Director of Operations

Quebecor Printing "I recently had the opportunity to introduce "Systematic Troubleshooting" to a large mid-west printing company for whom I was employed. The target audience was press operators and maintenance personnel. Our intention was twofold. First, we desired to increase the ability of people to identify root cause, improve their powers of observation and begin to think in a structured, rational way. Second, we wanted to create an opportunity for people to "bridge the gap" between maintenance and operations. Since these groups work so closely together, cooperation is essential. Traditionally these two groups develop "we/they" ways of thinking, reinforced by peer contact."

"I won't go into details of the program since you already have those. I will tell you that the program was successful by every measure we set up. During an overhaul cooperation was reported to be at levels no one could remember for the past 28 years (that was the longest anyone had been there) and attendance during this "unpleasant and dirty" job was 100%. We attributed this to the heightened sense of involvement. When I visited the job everyone from the newest helper to the press operator himself was covered in grime. They all worked together and I saw many instances of people talking about how the equipment worked and why the things they were correcting probably caused some of the operational problems over the past year. People were seeing beyond the job to the operational implications. I don't know if all of this can be attributed to the course content, but I do believe a significant credit goes to the work we did in class thinking, documenting and learning about our systems."

"As evidence of the programs acceptance; the technical supervisor mentioned, during a casual Sunday meeting, that he could see a distinct difference in the way the operators who attended the program were documenting troubles with the equipment and saw an improvement in the way were able to communicate relevant data to the maintenance people."

George Ferber, HRD Manager, Nabisco Div of Kraft Foods, Atlanta, GA E mail:

Michelin Tire Company "Systematic Troubleshooting teaches people to think logically and how to learn what they need to know about their machines." Those are the words of the trainer. He went on; "I like the way people in different trades learn to communicate by working together to solve problems. They make sketches and data tables for their own machines". Before buying Systematic Troubleshooting, this tire company looked at most other available courses. In their words, "Systematic Troubleshooting shines above the rest."

Macon Technical Institute uses Systematic Troubleshooting in a 9-month curriculum. They feel the program is "innovative and rich in content". They like the concepts and the emphasis on hands-on activities. The self-study materials fit in well.

Abbott Laboratories have incorporatated the program into continuing training for teaching field service people how to understand and troubleshoot medical diagnostic equipment.

Cincinatti Machine has purchased the program for use with their in-house technical service representatives and dealer field service people.


This program has been used by over a hundred organizations in a variety of forms. A few of these companies are:

SOME COURSE USERS: Machine, Quebecor Printing, Transcontinental Gas Pipeline, Tower Automotive, P.E. Biosystems, Rodel Inc, Manufacturers Association of Berks County PA, Malaysia France Institute, Finn PoM&M Mars, Allied Signal, Vistakon, Fluor-Daniel, American Maize Products, Detroit Edison, Amtrak, Harley Davidson, Chippewa Technical College, UniRoyal, Beecham Cosmetics, Nekoosa Papers, Ralph's Grocery Co, Abbott NW Hospital, PPG Industries, Miller Brewing Company, Michelin Tire, Shell Oil, LTV Steel Company, Thomas Steel Strip Corporation, Elkay Industries, United Globe Nippon, Amoco Pipeline Company, Sharp Electronics Canada, Zenith Electronics Corporation, Triton College, Prairie State College, Toyota Motor Mfg. Ameristeel, Cincinnati Machine, Finn Power International, Qualex (Div of Kodak), Landis Gardner, Abbott Laboratories, Tony's Pizza, DitchWitch, American Tool Company, Nabisco, Kraft Foods, Quad Graphics, General Mills, Labelaid, Lansing Electrical JATC, Guardian Industries, Associated Hygienic Products (AHP), ABB Inc, Precise Technology, Visteon, Qual Pak, HP Hood LLC, Canada Training Group, Hutchinson Technology, AGR Int, Manufacturers Resource Center, Bermuda Electric, Gregory Poole Caterpillar, Warren Distribution, FormFactor Inc, Sommerset Community College, Texas State Technical College, Sabic International (formerly GE Plastics), Republic Polytechnic University Singapore, Westinghouse Electric, Konica Minolta, Tetra Pak Arabia, NovoNordisk., Next Era Energy nuclear powerplant, Valpak, Graphic Packaging International, TRW Automotive, E & J Gallo Winery Spartanburg Community College, DeMoines Area Community College, SunEdison SOI Manufacturing

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