Troubleshooting Course Materials

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TROUBLESHOOTING TRAINING COURSE

FOR MAINTENANCE AND SERVICE PROFESSIONALS

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

About rental option

How does a MIMIC machine help in learning troubleshooting?

Learning materials included in the troubleshooting course

Instructor On A Disk Package

Troubleshooting course contents

What users say about Systematic Troubleshooting

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

Microcontroller-Based systems details

Circuit Boards and Digital Circuits
details


Curriculum 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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LEARNING MATERIALS:
working tools for the instructor and participant


SYSTEMATIC TROUBLESHOOTING (STS) PACKAGES and CASEBOOK

The powerful problem-solving principles of STS can be taught and applied in a variety of ways. Do-it-yourself options to fit your needs:

INSTRUCTOR ON A DISK PACKAGE

Content in this course is presented on four DVDs that have stop points about every two minutes for discussions, questions and hands-on activities. Can be presented by any maintenance person, technician, staff person or manager at a field location or in a plant or office.

TRAINER'S DEVELOPMENT PACKAGE

For trainers, managers or experienced instructors who need a flexible program that is easy to use and enables them to modify STS to fit their own styles and the needs of their company.

BASIC PACKAGE

For first-time users or people without instructing experience who need to improve the performance of technicians in maintenance or field service.

STS BOOTSTRAP

A version of the self-instructional Text-Workbook for use on a computer includes the TSAG and other tables for laptop use on the job.

TRANSITION TO TECHNOLOGY

This is an entirely separate do-it-yourself workshop for maintenance and field service people to help them in troubleshooting complex microcontroller-based processes and machines. The Systematic Troubleshooting course is not a prerequisite.

The Mimic is used in the three hands-on cases; Sequential Work Cell, Microcontroller-Based Process and Skilled Craft By Robot.

The focus is on locating and recording the status of inputs and outputs during normal operation and when there are problems.

CIRCUIT BOARDS AND DIGITAL LOGIC

In this self-instructional or instructor-led workshop, students apply the STS troublehooting methods to the Mimic's digital logic circuits and other systems.

They learn how the various circuits work, how to take voltage readings on microchips and other components.

In five "story problems" about stressful applications in industry and the military, they work in pairs to find causes of problems stemming from the circuits.

"INSTRUCTOR ON A DISK PACKAGE"

Improving the troubleshooting of your people is important. You know that. But you’re not sure how to give your people these skills. Now there’s a new STS method. No instructor needed. You can use it anywhere. Home base or in the field. Groups of two to twenty-two.

This program combines the best features of many teaching techniques to produce a highly effective experience that is easy and fun for both the leader and learner. It distills the knowledge the author gained through many years in instructional design and in leading STS workshops.

Course content is delivered on video using film, photos, artwork and text to improve attention and learning.

weld line
One of many machine and process shots in video

Socrates taught that people learn best when they contribute. For this reason, the video is programmed to stop frequently for student discussions and questions. Positive reinforcement is given for student answers. This stimulates participation. The Leader’s Guide explains what to do or say at each stop point.

A wide variety of activities is provided including working with a candy bar process, flying a plane, solving digital logic problems, finding root causes of a failed bearing and solving a murder case.

No one gets bored.

plane starting
Mimic becomes bomber while pilot and copilot fly

Experience in teaching STS has shown that people who work with their hands get enthusiastic, involved and learn best when they can work with something mechanical or electrical. They also like the challenge of solving real problems with actual machines and processes. Hand and mind activities, which are also introduced at video stops, are taken directly from proven, traditional STS workshops. Instructor-On-A-Disk uses the same student activity books as the instructor-led versions of STS. People work in teams of two throughout the course. This fosters communication, teamwork, cross-trades learning and sharing of knowledge.

As in the conventional STS versions, Instructor-On-A-Disk builds up to a final learning experience in which students prepare a problem for their teammate to solve. They take roles of observer and troubleshooter. The observer evaluates the troubleshooter’s performance as he or she applies STS principles in gathering data, analyzing and finding the most likely causes of the problem. Then the observer and troubleshooter switch roles. This session is where participants realize the value of what they learned and see how everything fits together. It’s satisfying to see students becoming “instructors” as they watch their partner troubleshooting.

stop frame
Video stops for participation. Is re-started on screen.

The Leader’s Guide includes a full script of the video and the running time of each segment. At the end of each segment, the video stops. A video frame appears showing the stop number. This is keyed to a box in the leader’s guide with instructions for what the leaders says or does at that point. The video stays on hold. When the activity at the stop is completed, the leader clicks a re-start button on the screen. The video plays the next scripted segment.

Leaders Guide
Leader's Guide tells what to say and do at stop points.

TRAINER'S TOOLBOX

Instructor-On-A-Disk also includes a “Trainer’s Toolbox”. This includes optional activities to expand and enrich the learning experiences of your students. The materials also help them to apply the principles in STS to the equipment and processes they work with on the job.

The materials include: Industrial Applications, Training Planner for creating programs that accomplish your needs (even if you’ve never designed training before), Root Cause Analysis, how to find a corrective action that will prevent the problem from ever happening again, STS Performance Test evaluate how well your people understand course concepts and can apply them for solving problems. The Trainer’s Toolbox also contains a full set of masters for the overhead transparencies.

If you would like a sample DVD and Leader’s Guide of a part of this program, just e mail or call with your current address. If you can’t find your original preview materials, please request replacement. The video is programmed with frequent auto-stop points for class interaction. These include questions, discussions and numerous hands-on activities with the Mimic machine and course materials. When the students finish each discussion or activity, the leader re-starts the video with a mouse click.

The instructor leads the class using a color-coded guide with a complete transcript of the video and instructions on what to say and do at each stop point. The video transcript enables the leader to anticipate and prepare for the interactions at the stop points. It also gives the leader an option to personally present any parts of the course and provides a backup if the computer fails.

Students use an Activity Book that includes instructions and forms for use in activities. The book includes summaries on how to use each type of sketch and table, so students don't need to take notes.

A conventional overhead projector and slides supplement the video so that the instructor can write student responses on the slides to show how the tables used in the course are filled out. Over 70 numbered slides with references keyed to the script are provided.

To find out more, go to the Preview Page, check the "Instructor-On-A-Disk" box and e mail the form to us or give us a call.

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TRAINER'S DEVELOPMENT PACKAGE

This is the top-level package for the professional trainer or manager who wants the tools needed to get all the benefits STS can provide.

In addition to what's in the Basic Package, you get a Presenter's Notebook, a Training Planner and a Powerpoint presentation with script on CD. Each of these materials is described below.

PRESENTER'S NOTEBOOK

Once you have taught a couple of classes, or if you are an experienced trainer, you may want to tailor the course to fit your own presentation style, the type of students you have and the needs of your company. And, you may want an easy to use outline or Powerpoint format, rather that a complete script as you present the course.

The Presenter's Notebook is the course designer's own personal customized version used in presenting workshops. It contains less detail than the Administrator's Guide, is arranged in a different sequence and includes a variety of new activities to stimulate class interaction.

Also, after every workshop the designer writes in red pen, any changes that might clarify explanation or fine-tune technical content. These revisions are incorporated in the Notebook. When you purchase the course, you get the very latest version.

The Notebook also simplifies preparation. Planning on what to include in the workshop is done using a check-box method. The instructor can adapt style to personal preference, select content and adjust workshop length. Masters for overhead transparencies are provided and correspond with the Powerpoint program.

POWERPOINT PRESENTATION

A complete Powerpoint presentation for doing an entire workshop based on the material in the Presenter's Notebook is included with this package. It includes all the slides as well as a presentation outline and notes.

TRAINER'S TOOLBOX

The Trainer's Development Package also includes a “Trainer’s Toolbox”. This includes optional activities to expand and enrich the learning experiences of your students. The materials also help them to apply the principles in STS to the equipment and processes they work with on the job.

The materials include: Industrial Applications, Training Planner for creating programs that accomplish your needs (even if you’ve never designed training before), Root Cause Analysis, how to find a corrective action that will prevent the problem from ever happening again, STS Performance Test evaluate how well your people understand course concepts and can apply them for solving problems. The Trainer’s Toolbox also contains a full set of masters for the overhead transparencies.

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BASIC PACKAGE

Even if you've never taught a course before, The Basic Package includes everything you need be an instructor. You learn the course using the self-instructional Text-Workbook and MIMIC machine. Your students will think you've been a teacher all your life as you use the complete script in the Administrator's Guide. Activity Books provide all the materials your students need. One MIMIC is included, which enables you to teach one team of two people at a time. If you wan't larger classes, just add a MIMIC machine for each additional team.

The Package includes a Text-Workbook, an Administrator’s Guide, five student Activity Books, and a MIMIC machine. Each of these materials is described below.

TEXT-WORKBOOK

The Text-Workbook contains the complete content of the course, including all hands-on activities. Instructors use it to learn the content and activities in the course and as a reference during class sessions.

This comprehensive 244-page learning tool is a combination of easy-to-read instruction, illustrations, activities and discussion questions. It includes all materials needed for classroom activities or self-study, including answers for all activities.

If you plan to have participants learn on their own, or you want to combine self-instruction with group sessions, you can order a self-instructional Text-Workbook for each participant and use it in place of the Activity Book.

ADMINISTRATOR'S GUIDE

This 308-page reference is the ultimate instructor's resource. It is ideal for the new instructor, because it contains complete instructions for planning a class, a full script on everything to say and detailed instructions on all activities and how to use the MIMIC machine. Master copies of overhead transparencies are included.

For the more advanced instructor, fifteen case studies in various fields are also provided as well as a script for tailoring the program to the requirements of production workers. Information for configuring the MIMIC for your own custom activities is included. Answers for all activities and performance evaluation materials are provided. If you want to use a combination of self-instruction and group sessions, instructions are included for this format.

ACTIVITY BOOK

The Systematic Troubleshooting course involves activities that require working with machines and processes, making sketches, interpreting information, filling out tables and teamwork with a partner. This Activity Book provides all the materials a participant needs and facilitates the building of an information file on the equipment they are troubleshooting. (Just like the one you hope they build on the equipment in your plant.) A reference section, with materials you can copy for use on the job, includes concise explanations of each form and table.

MIMIC machine

The MIMIC enables participants to apply what they learn in the course by working with a real machine. Click here for more about the MIMIC

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STS BOOTSTRAP

Systematic Troubleshooting Bootstrap is a computer-format version of the original self-instructional Text Workbook. The Text-Workbook is the basis of the Systematic Troubleshooting course. The new format is great for people on the road or who are never without their laptop. And, because class time is reduced, it saves costs of lost time on the job, instructors and training rooms.

Laptop in use

STS is based on the premise that field service and maintenance people learn best and remember longest when they have a physical device with which to work and real problems to solve. For that reason, the Text-Workbook is designed for use with the Mimic. The problems presented require an understanding of the Mimic, its systems and the processes it controls.

The course is designed for teams of two working together or individuals working alone. Partners pool their mental resources and learn from each other. In the final activity, one person sets up a problem for the other to solve and critiques the partner’s performance. Then they reverse roles. People working alone will have easy access to all instructions and answers for activities and reviews.

Content is in a PDF format divided into twelve segments, each with cover sheets, hands-on activities and review questions. A print version of the Text-Workbook is included for those that prefer paper and pencil.

The five data tables in STS are all in Microsoft Word table format, so information can be keyed-in and displayed on computer screens. The masters for these tables are in templates that can be used over and over without losing their original structure. People who like to make sketches and color-code them in their favorite CAD program can do so. Or paper and pencil in black and colors can be used. Drawings can, of course, be scanned into a computer. This works great for people who are never without their laptop.

In addition to the Text-Workbook, STS Bootstrap includes a guide for the supervisor. It gives suggestions for introducing the course, motivating students and explaining expectations.

When students have completed each group of study assignments, activities and review questions, the leader meets with them to answer questions, discuss applications and review activities. Optional tests of performance and knowledge may be given at the end of the course. Test results required may be explained up front as well as changes in job status or pay that may be expected by those who complete the course successfully

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Phone: 847 729 4550
E Mail: bobfrye@troubleshootingcourse.com