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There are many things that need to be considered while trying to speed up any control system troubleshooting. The picture below shows some of them:

Image result for troubleshooting

The Downtime Reduction Group has developed a bullet-proof fault detection algorithm that utilizes human participation and anticipation during the search for the problem. For example, when machine operators make a comparison of two or more multi-color indicators on the screen, they do it really fast without visible effort.

How  are we going to do the troubleshooting?

Imaging, that you have an alarm screen with approximately 50 listed alarms and indicators of real I/Os, all in different colors, depending on their actual state. Every I/O will be displayed with three color indicators side-by-side. How fast do you think it would take for the operator to observe an alarm screen with 50 listed inputs? Do you think it can be done in ONE second? Maybe TWO? A system with 30 screens and total of 1,500 I/Os can be scanned by the machine operator in 60 seconds!

What else are we going to do?

Please refer to Reconfigure Control Systems for details.

All associated documentation, such as electrical schematics, P&ID – that is process and instrumentation diagram — with all devices, wiring diagrams, PLC source codes, HMI graphics, operation and maintenance manuals, all of them must be available or must be developed if they don’t exist. We offer a Unified Logic Diagram Design for every individual part of the control system, including communication, HMI displays, wiring diagrams, and PLC logic, all on the same drawing.

An actual troubleshooting time takes a few minutes not hours.

Consider taking a crash course in the Downtime Reduction Methodology. It takes only two day. You can find its content at Downtime Reduction School.