THE SEVEN STEPS OF :

TROUBLE SHOOTING PROCESS

Step 4
Step 1 Step 2 Step 3
PENUGASAN MEKANIK
PENEGASAN GEJALA MENENTUKAN KEMUNG PERSIAPAN
KERUSAKAN KINAN - KEMUNGKINAN
TERJADINYA KERUSAKAN
Step 5
PENJELASAN KERUSAKAN
DENGAN MENGINTERVIEW
•MECHANIC COMP. - OPERATOR
•TOOLINGS - MEKANIK CUST
CUSTOMER •QA SHEET
- COMPLAIN •SHOP MANUAL Step 6
- INFORMASI •PK2
•PSN COUNTER CHECK
KONDISI UNIT DENGAN
PERLU PERLU DATA YANG ADA
KEJELIAN KETELITIAN

Step 7

MENENTUKAN
TECHNICAL & KERUSAKAN
APPLICATION TECHNICAL KNOWLEDGE
KNOWLEDGE

• TROUBLE SHOOTING CHART 8 STEPS

• SHOP MANUAL TROUBLE ANALYSIS
• PARTS & SERVICE NEWS PROCESS
BACK

PPT/Amin/Press_Jan’03
8 STEPS :
TROUBLE ANALYSIS PROCESS
Step 1 Step 2 Step 3 Step 4
PENGAMATAN
TROUBLE SHOOTING POSSIBILITY LAPANGAN DATA
CHART CAUSES ( DIAGNOSTIC )

Step 5

ANALYSIS

TROUBLE Step 6

SUSPECTED
PERLU PERLU CAUSE
KEJELIAN OPEN MIND

Step 7

KESIMPULAN
TECHNICAL ATTITUDE
KNOWLEDGE ( HABIT )

Step 8

REPORTING ACTION FOR

SYSTEM IMPROVEMENT
 THE EIGHT STEPS OF TROUBLE ANAYSIS PROCESS

MEASUREMENT DATA OF COMPONENT

= ………………………………….
MODEL = …………………. S / N = ………… E / N = …………. DEL DATE = …………..
POSSIBILITY CAUSE PART NAME STD SIZE ACTUAL DATA DRAWING / SKETS

MEKANISME TERJADINYA KERUSAKAN

PART NAME MEKANISME KERUSAKAN

DIAGNOSTIC DATA
PART NAME FAILURE SIGNS CAUSES DRAWING / FOTOGRAPH

TROUBLE ANALYSIS
PARTS NAME ANALYS SUSPECTED CAUSE CONCLUSION ACTION &
IMPROVEMENT
 ENGINE OIL CONSUMPTION CHECK SHEET

CUSTOMER NAMA :
LOCATION :
TYPE OF BUSINESS :

DATA UNIT
MODEL SERIAL ENGINE DELIVERY INSPECTION REMARK
NOMOR MODEL S/N DATE DATE SMR

ENGINE OIL
PRODUCT CLASS VISCOSITY DATA PAP

AIR SYSTEM
SUCTION PIPE KONDISI SAMBUNGAN ANTARA TUBE & HOSE
Clamp kendor Tube baik / retak / aus
Clamp kencang Hose baik / retak / ada alur
………………. …………………………….
AIR CLEANER DIBERSIHKAN SETIAP …. Hrs/ day 50 hours
250 hours 100 hours
DIGANTI SETIAP DIGANTI SETIAP 1000 HOURS …………. hours
BAGAIMANA KEADAAN SEAL DAN HOUSINGNYA

FUEL DATA :
TEST SOLAR Ya DATA :
Tidak

VISUAL CHECK :
CHECK KEBOCORAN OIL
DIBAGIAN LUAR ( EXTERNAL LEAKAGE )
CHECK KEBOCORAN OIL PADA
FRONT / REAR SEAL
MEASUREMENT DATA
ITEM LOW IDLE HIGH IDLE TGL. MONITORING PADA SAAT OPERASI
STD ACT STD ACT
ENGINE RPM

BLOW BY PRESSURE
mmH2O

ENGINE OIL PRESSURE

Kg/cm2

ENGINE OIL TEMP

ENGINE WATER TEMP

EXHAUST GAS TEMP

EXHAUST GAS COLOUR

Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Cyl. 6 STD REMARKS

ENGINE COMPRESSION
NOZZLE PRESSURE

PERIODICAL MAINTENANCE
DATE SMR KETERANGAN PENGGANTIAN OIL, ELEMENT, WATER, GREASE DLL
 BAGAN PROCES PERBAIKAN
EVALUASI PROCESS PELAKSANAAN
PELAKSANAAN
KEBUTUHAN ORDER SUPPLY PARTS REPAIR /
OLEH PEMILIK
PARTS PARTS OVERHAUL
 HYSTORICAL
UNIT   AVAILABILITY  PSN
GENUINE
PARTS PARTS
 PSN  SHOP
 KNOW  SCHEDULE MANUAL
 COMPONENT LEWDGE OVERHAUL
MODIFICATION
DATA
 REUSABLE PARTS  MENGURAN
GI BREAK
REPAIR DOWN TIME
AND SCHEDULE REPAIR UNIT  DAYA GUNA
OVERHAUL AND OVERHAUL OPERATION RFU ALAT
TINGGI
 SPO  PRODUCTIF
 HYSTORICAL UNIT ITAS ALAT
 STD COMP. LIFE BAD TINGGI
CONDITION  BIAYA
BREAK DOWN OPERASI
DISTRIBUTOR RENDAH
SUPPORT

PELAKSANAAN REC. PART ATAU PROCES SUPPLY PARTS PELAKSANAAN

OLEH EVALUASI ORDER REPAIR/
DISTRIBUTOR KEBUTUHAN PARTS PARTS OVERHAUL
AVAILABILITY
PARTS • PK 2 ROI
 PSN GENUINE • SHOP MANUAL
 PARTS SCHEDULE • PSN
COMPONENT
MODIFICATION REPAIR/
DATA OVERHAUL
 REUSABLE PART
 HYSTORICAL UNIT
 Normal Proper Operation
Production Set Up & Adjustment
MAINTENANCE & REMEDIAL
Cleaning
Lubrication
Routine
Tightening
Maintenance
Routine Inspection
Minor Servicing

Inspection
Priodic
Maintenance Servicing
Maintenance
Overhaul

Condition Monitoring And

Predictive Machine Diagnosis
Maintenance Parts Replacement And
Overhaul

Early Detection And Prompt

Breakdown Reporting
Maintenance
Repairs

Stregthening
Reliability
Load Reduction
Remedial
Inspection Procedures
Maintainability Servicing Procedures
Servicing Quality
 FLOW OF INFORMATION
CUSTOMER

UT BRANCH COLLECTING DATA

- CUSTOMER NAME
- DATA MACHINE & LOCATION
- DATA PROBLEM
TSR / TROUBLE RECORDS
- APPLICATION UNIT

NEW NO NO
IMPORTANT
PRODUCT INFORMATION
PROBLEM

INFO TO BRANCH
- HOW TO REPAIR YES
- HOW TO MAINTENANCE
- HOW TO MONITOR SERVICE DIVISION
ANALYSIS/INVESTIGATION

INFORMATION
TSI / LETTER / ETR
(INFO TO PRINCIPAL)

ANALYSIS/INVESTIGATION
( BY PRINCIPAL )

Note:
TSI = Technical Service Information
FEED BACK TSI fr PRINCIPAL
TSR = Technical Service Report
ETR = Emergency Trouble Report
SERVICE DIVISION
SUMMARIZED

SERVICE DIVISION MONITOR