WORK TYPE manual

MECHANICAL

Use this category when the downtime is caused by a mechanical failure, wear, damage, or physical blockage of the machine. Typical examples include damaged or misaligned belts, chains, bearings, rollers, gears, springs, guide rails, shafts, broken brackets, loose mechanical parts, or jammed mechanisms. It also applies when a mechanical component needs adjustment, alignment, or replacement. For example, if an electric motor cannot run because its bearing is seized, the root cause is mechanical and the category should be MECHANICAL.

ELECTRICAL ≤48V

Use this category for failures in low-voltage electrical circuits up to 48 V, most commonly 24 V DC. Typical examples include damaged or broken cables, connectors, terminals, 24 V power supplies, fuses, relays, coils, poor electrical contacts, or loss of power in a control circuit. If a sensor itself is working correctly but does not receive 24 V due to a broken cable, this category should be used. If the sensor itself is faulty or provides an incorrect measurement, use CONTROL & INSTRUMENTS instead.

ELECTRICAL >48V

Use this category for failures related to the power electrical system above 48 V, typically 230 V or 400 V. Examples include the main machine power supply, circuit breakers, power contactors, motor power circuits, frequency drives from the power-supply point of view, electric motors, heating elements, or other high-power electrical components. For example, if a motor fails due to damaged windings, a missing phase, or a 400 V power supply issue, use ELECTRICAL >48V.

CONTROL & INSTRUMENTS

Use this category when the failure is related to equipment whose purpose is to sense, measure, detect, or provide information to the control system. Typical examples include photoelectric sensors, inductive sensors, limit switches, encoders, readers, scanners, cameras, pressure sensors, temperature sensors, and other measuring devices. This also includes incorrect sensor positioning, adjustment, or calibration when it causes the machine to receive an incorrect signal. In simple terms: if the machine cannot correctly “see,” “detect,” or “measure” something, use CONTROL & INSTRUMENTS.

PNEUMATIC & HYDRAULICS

Use this category for failures related to compressed air or hydraulic systems. Examples include leaks, damaged hoses, faulty fittings, valves, solenoid valves, pneumatic or hydraulic cylinders, pressure regulators, insufficient air pressure, hydraulic oil problems, pumps, or hydraulic manifolds. A typical example would be a pusher or another mechanism that does not move because the cylinder is not generating force, a valve is not switching, or compressed air is leaking.

SOFTWARE/PLC

Use this category when the downtime is caused by software, PLC programming, communication, or machine control logic, rather than by a physically damaged component. Examples include PLC program errors, incorrect sequences, recipe or parameter problems, communication failures between the PLC and another device, HMI software problems, industrial network communication issues, or situations where a program needs to be modified or reloaded. If a sensor provides the correct signal but the PLC reacts incorrectly, use SOFTWARE/PLC.

HUMAN ERROR

Use this category only when it has been confirmed that the downtime was caused by incorrect operation or human intervention, rather than by a technical failure of the machine. Examples include incorrect machine settings, incorrectly loaded material, an object accidentally left inside the machine, incorrect installation of a component after maintenance, selection of the wrong program or recipe, or failure to follow the correct operating procedure. Do not use this category automatically just because the technical cause is unknown — there should be a reasonable indication that human action was the main cause.

OTHER

Use this category only when none of the other categories reasonably describes the actual cause of the downtime. This may include an unusual external influence or a very specific event that is not mechanical, electrical, pneumatic, control-related, software-related, or caused by human error. OTHER should be used as little as possible, and whenever it is selected, the technician should briefly describe the actual cause of the downtime in the note/description field.