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Troubleshooting at the Machine (QR on the Machine)

A 3-minute fix instead of 45 minutes of waiting.

🔧 MAINTENANCE & PROBLEMS
Standard faults cause a disproportionate amount of downtime - not because they are hard, but because the operator does not know how.
-40%
MTTR on standard faults
Top 10
error codes per line
3 min
instead of 45 min downtime

The typical pattern: the operator waits for the shift lead, who waits for service, service arrives later and fixes it in 3 minutes. Downtime: 45 minutes. What you document: the top 10 error codes per line with their fix, sensor adjustment, filter and belt tracking correction, software resets - and the clear boundary of when to call service.

⚠️
The trigger - how do you recognize it?
  • Operators call service for the same standard faults over and over
  • The fault documentation is an Excel list nobody knows about
  • Experienced operators fix 80% themselves, new ones only 20%
  • MTTR is far higher than the pure repair time
ℹ️
How it works with GIRI

QR code right at the typical fault location (control cabinet, display, sensor). One instruction per error code - not one for all. Safety checks as the first steps, a clear escalation boundary: self-service up to here, call service beyond that.

💡
The value
  • -40% MTTR on standard faults
  • Operators become self-service capable for routine problems
  • The service team is relieved - only called for real problems
  • Fault knowledge is captured systematically instead of hoarded in heads
💡
Typical users
  • Complex lines with many error codes
  • 24/7 production (service not always on site)
  • Several identical machines (knowledge sharing)
  • Industries with high downtime cost per minute
⚠️
What you want to avoid
  • Expecting operators to do complex repairs - draw a clean boundary
  • Troubleshooting without safety steps - power off, release pressure, then repair
  • Fault instructions without escalation - what if the fix does not work?
KPI figures are industry benchmarks (SwipeGuide, REWO), not a GIRI guarantee.
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