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About this troubleshooting course
How does a MIMIC machine help in learning
troubleshooting?
Troubleshooting course contents
Instructor On A Disk Package
What users say about Systematic Troubleshooting
FAQ's (Frequently Asked Questions) about the troubleshooting course
Links to information about maintenance and troubleshooting
IDEAS! on training and troubleshooting
About the creators of Systematic Troubleshooting
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LEARNING MATERIALS:
working tools for the
instructor and participant
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:
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.
For first-time users or people without instructing experience who need to improve the performance of technicians in
maintenance or field service
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.
Two workshop packages are available that apply the principles of STS to applications such as troubleshooting
circuit boards and digital logic microchips and automated systems including industrial robots and
microcontroller-based processes. They provide a foundation for building specialized training on your own
processes whether they involve physical equipment or administrative methods. The goals of the programs are to
strengthen analytical and creative mental ability to enable people to understand complex systems and solve problems.
People learn to adapt STS sketches and tables as aids in these goals. These are all basic level courses that do not
require knowledge of electronics, microcontrollers or programming.
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.
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.
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.
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.
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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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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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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These automation applications provide an important transition from the basic STS course to highly automated,
complex and technical equipment. They apply the basic principles in STS and add new tools and techniques.
These are thoroughly developed cases that will challenge your people to apply
their mental skills in solving machine and process problems in digital logic and microcontroller-based equipment.
These workshop materials have activities for self-instruction in teams and classroom use.
All three Automation applications include Facilitator’s Guide
and Activity Books.
Guided Mimic-Based Self-Instruction in Teams.
By recording voltages and logic states, participants learn how a circuit works and to create a “fingerprint”
that helps them troubleshoot. Electronics training or experience is not needed. It’s a learn-by-doing course with
no arithmetic and very little reading.
People use the MIMIC, which is a working circuit board containing components such as digital logic gates,
comparitors, inverters, potentiometers, switches, phototransistors and LEDs. Faults can be introduced using
switches. Participants learn to read diagrams and to locate components, test points and adjustments.
Participants apply what they learned in STS by putting information in tables that provide a record of the readings
on the equipment when it is working right. (We call this a “fingerprint”) With this information, they can
troubleshoot! The Troubleshooting Action Guide (TSAG) from Systematic Troubleshooting is used for determining
the causes of problems.
Many courses require a person to study long explanations of things they don’t really want to know.
This course starts with the fun stuff. An appendix provides information only as people need or want it.
It is not required reading. It has the following four sections:
Essential Information from Systematic Troubleshooting
This section has information about the MIMIC that you will need for doing the activities. It explains how to
set up the machine for normal operations, identifies the controls and provides a diagram of the inputs,
outputs and logic.
How It Works
Here learners will find information about electronics to help them in understanding how the MIMIC circuits work.
This background will be useful in troubleshooting the MIMIC as well as the equipment they service.
How To Troubleshoot Electrical Stuff
If people are totally new to taking electrical measurements and troubleshooting electrical devices, this section
will give them a start. It explains how to use a multimeter in trouble shooting common household devices.
How to Troubleshoot at the Board Level
In this course learners work with a single board with multiple circuits. Does this apply at the board level? Yes.
The principles of taking measurements, producing Settings-Measurement Tables, learning how the systems work,
and measuring test points apply to both single and board-level troubleshooting.
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This package presents a variety of activities you can use to help people make the transition from the
basic principles learned in STS to jobs involving automated equipment. Your people develop their
analytical and creative ability, learn methods for understanding complex systems and solve problems
involving these systems. No knowledge of electronics, microcontrollers or programming is required.
All workshops are hands-on using the Mimic configured to represent the following applications:
* sequential materials transfer system
* microcontroller-based industrial process
* input data to microcontrollers
* robot positioning system.
* painting process characteristics including air and paint pressures, flow rates,spray
patterns and the art of application.
* observing pulses with an oscilloscope.
* color-coding a drawing of the Mimic circuit board to identify the circuits and
components controlling each axis of the robot.
The first activity involves an industrial work cell with two machining stations, a punch press, a drill press
and a parts transfer robot. Each work station has a clamping device and the robot has a gripper. Using the Mimic
control panel, the learner steps the operation through the sequence needed to transfer the work in progress
from one work station to the other. All goes well until a problem develops. The sequence stops.
However, using an adaptation of one of the STS tables, called a Sequence Fingerprint, the learner is able to
narrow the cause to one device.
In the second Activity, participants set-up the Mimic to represent a process that produces compressed air for a
manufacturing plant. The air is at a controlled temperature and pressure. Using the Mimic’s controls and
indicator lights, learners run the system from start-up through its control cycle as it maintains tank
pressure, air temperature and line pressure at the output to the plant. Using data for normal operation,
participants build tables to show critical voltages, indicator light status and dial positions.
Diagram shows Mimic input/output data at microcontroller pins.
The Activity provides the instructor with a foundation for teaching fundamental concepts and mental skills
needed for troubleshooting a complex process.
Participants will adapt the familiar STS methods to give them the understanding they need. They develop
their creativity and mental flexibility by learning how the Mimic can provide input data to the process and
outputs from the PLC. A new input / output sketch of the Mimic helps in gaining this knowledge.
Learners will use the Mimic to learn or re-enforce PLC and data-handling concepts essential in all
microcontroller applications.
The course also includes an optional activity that teaches the basics of observing pulses with an oscilloscope.
You can use your own scope, or you can order an inexpensive one that uses your laptop.
Another Activity puts the learner on the shop floor in a pickup truck assembly plant. The line is shut down because of a
problem in spray painting. The finish, applied by robots, is un-acceptable. The foreman is livid.
Problems develop on robotic spray painting line
New on the job, the maintenance person must acquire knowledge of robotics as well as in the art of spray painting to be
effective in problem solving.
The Mimic becomes a closed-loop feedback system to a three-axis robot, supplying encoder data and pulses to stepper
motors.
The first problem involves the accuracy of the robot positioning system. Participants build Settings-Measurement Tables
on which normal readings at the Mimic’s digital and analog test points are entered. A diagram shows how the data on the
table relates to pins on the microcontroller chip.
A major part of this Activity is devoted to a achieving a full understanding of how a robot positioning system works.
Data tables and sketches illustrate the concepts and Kozlinski, a fictional maintenance guy that knows robots, is
introduced to provide a realistic human touch in the learning process.
When the background learning is completed, the participants go back to the original problem in the painting cell.
Working alone or with a partner, they use the Troubleshooting Action guide to find the cause.
With the positioning problem solved, learners get a rude surprise. This time there is a defect in the paint finish.
The line is stopped again. In this optional part of this section, participants must learn the complex art of spray
painting. This involves paint characteristics, the variables of air and paint pressures and flow rates, spray patterns and the
art of application. Using data from an actual truck painting line, learners complete a matrix (Process Table) that
correlates the finish defects with factors affecting the process.
Then, its back to the Troubleshooting Action Guide to find the cause of this new problem.
In a final optional Activity, participants color-code a drawing of the Mimic circuit board to identify the circuits
and components controlling each axis of the robot. They use circuit diagrams so they can locate components on the board.
They also find points on the board where an oscilloscope can be connected to count pulses to stepper motors.
The course also includes an optional activity that teaches the basics of observing pulses with an oscilloscope.
You can use your own scope, or you can order an inexpesive one that uses your laptop.
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By using the methods in Systematic Troubleshooting throughout an organization and developing a culture
that allows people to solve problems, make decisions and take independent action at their own job site it is
possible to improve the effectiveness so dramatically that it can save an entire company.
That is just what happened to an Ohio manufacturer. The company was saved because of the full support of
management, use of STS by ALL employees, a document retrieval system, homework assignments
and clear expectations.
The materials in this package include a persuasive, self-paced DVD for executives that presents
the benefits and an action plan. The package provides a blueprint for application of STS by all employees
in all departments. A printed summary of the DVD is also provided. Also included in the kit, is a candid transcript of an
interview with actual users who implemented STS in a failing company.
You might also want to order the Administrative Field Service Management
Activity described above (in the Presenter's Casebook) as an example of applying STS in non-production departments.
NO EXPERIENCE AT TEACHING CLASSES?
Perhaps you are one of those experts with talents who must train others. Or
you may be a trainer who must master new technology, then help others to
learn those subjects. Maybe you’ve been asked to present the Systematic
Troubleshooting course. Even though STS has complete guides for the instructor,
you or your people may still need a boost to get started as a teacher.
For these people, the Learning Shop is now re-issuing on DVD and in print, “The Instructor’s Shop” a proven
course that enables experts to pass their knowledge and skill on to others.
It features a user’s guide that provides answers to questions and activities for a
self-learner as well as a guide for classroom presentation.
Professionally produced video and an interactive workbook with an easy style are included. Content includes
participation activities, step-by-step teaching procedures and self-evaluation guides. Learners benefit from
practical, fog-free content. Video, text, cartoons and participation keep attention high, make learning easier
and help people remember what’s important.
The Instructor Shop has a two-part DVD video called “How To Plan and
Teach a Class”. It provides demonstrations of such essential skills as; controlling your fear of leading a class;
how to get your class off to a good start; discovering participant goals and expectations;
how to give a good lecture; conducting a participative lecture; leading a discussion; giving a demonstration.
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Phone: 847 729
4550
E Mail:
bobfrye@troubleshootingcourse.com
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