Operating problem review · no automatic root-cause claim
Troubleshoot the Factory from Symptoms to Evidence
Describe what can be observed before naming a cause: where the symptom appears, how often, under which product and bottle format, current versus target output, which alarms or stops occur, what changed, which materials are in use and how upstream and downstream equipment behave at the same time.
Symptom entry points
Choose the observable problem first
01 · Buyer or factory inputs
Information the decision needs
- Observable symptom and line area
- Frequency and time pattern
- Current and target BPH
- Bottle format and material lot
- Alarm, stop, reject and quality-hold records
- Settings and recent changes
- Safe photos or videos
- Utility readings and maintenance history where relevant
02 · Operating objective
What completion should achieve
Create a bounded problem statement, preserve evidence and assign the next safe investigation without making an unsupported engineering conclusion.
03 · Required controls
Turn the objective into controlled work
- 01
Protect people and product first; stop and escalate unsafe conditions
- 02
Record the state before clearing alarms or changing settings
- 03
Use one time window for counts and losses
- 04
Change one controlled factor at a time when authorized
- 05
Keep material lot, shift and format context attached
- 06
Separate containment from confirmed corrective action
- 07
Verify the result across representative conditions before closure
04 · Factory interfaces
What connects to this decision
- Low output: schedule, stops, speed, yield and quality hold
- Frequent stops: alarms, material supply, accumulation and restart sequence
- Rejected bottles: source, type, line position and lot
- Unstable filling or caps: container, product, supply, settings and inspection
- Labels or packing: container condition, material, speed, accumulation and downstream flow
- Utility instability: measured demand, quality, pressure/flow/voltage and time correlation
05 · Evidence to collect
Records that make review possible
- Time-stamped symptom log
- Production, downtime and reject reports
- Alarm and setting record
- Bottle, cap, label and pack specifications
- Material lot and incoming result
- Maintenance work and replacement history
- Safe photos, videos and measurements
06 · Common failure modes
Do not confuse a pattern with a confirmed cause
1Clearing alarms without recording them
2Making several changes together
3Blaming one machine without same-window interface evidence
4Continuing to produce uncertain product without status control
5Closing the issue after one short successful run
07 · Responsibility boundary
Name who confirms each part
| Role | Possible responsibility in this stage |
|---|---|
| Operator / supervisor | Describe and contain the symptom and preserve the initial state. |
| Maintenance | Investigate safely and document tests, changes and parts. |
| Quality | Control product status and connect rejects or holds to the event. |
| Supplier / Allot Tech | Review structured evidence and confirm the scoped next step. |
08 · Completion criteria
Evidence that the stage can advance
- The problem statement is measurable
- Evidence covers relevant interfaces and conditions
- Containment protects people and product
- The confirmed cause is distinguished from hypothesis
- Corrective action is verified under representative operation
Decision support
Questions operating teams ask
Should the line keep running while a fault is investigated?
Only within approved safety, quality and operating controls. Stop and escalate any condition that could endanger people, equipment or product status.
Why record the state before a reset?
Alarms, settings, material, counts and upstream/downstream conditions can disappear after recovery, removing evidence needed to identify the mechanism.
Editorial responsibility: Allot Tech (Suzhou) Co., Ltd. · Last updated .