About the project
Diagnosing issues in high-tech machine systems requires expertise from multiple disciplines and the right diagnostic tools. One of these tools is the Deterministic Diagnostic Flow (DDF), which helps identify potential failures based on specific system errors. By collaborating with stakeholders across engineering, design and support, we mapped out the possible failure modes of a recurring error and developed a structured approach to solving it.
The task
The objective of this project was to identify all possible failure modes linked to a specific system error. By systematically diagnosing the components, the team aimed to trace the problem back to one root cause. Once identified and fixed, the machine could quickly be brought back into operation. Each DDF was documented, saved and reused whenever the same error occurred in the future, providing a repeatable solution that reduced troubleshooting time.
How we worked
To tackle the problem effectively, we organized a workshop session with stakeholders including customer support teams, industrial engineers and system designers. During this session, we:
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Mapped out all possible causes of the error
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Discussed the likelihood of each potential failure mode
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Identified the actions needed to resolve each scenario
This collaborative approach ensured that the most realistic and effective solutions were prioritized.
The solution
By documenting the failure modes and linking them to clear actions, we created a practical tool that has since proven highly effective. Each time the error occurs, the DDF guides engineers directly toward the root cause.
This approach delivered:
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Faster resolution of system issues
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Reduced downtime and production loss
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A reusable diagnostic framework for future troubleshooting
The DDF has become a reliable method for troubleshooting, ensuring that complex machines can return to full operation in less time, with greater accuracy.
