33rd FVI Expert Breakfast

Topic: "The Devil in the Details" – Systematic troubleshooting instead of blind actionism.

In this session, David Polinski showed how to proceed methodically with paper and pen (or flipchart) when the house is on fire.

• The "3-Step Method": When the door opens and someone shouts "Machine broken!", everyone runs and swaps parts. Wrong! David recommends:

1. Define the problem: What exactly is not working? ("Measurement Skip 4 defective, Skip 3 works").
2. Gather facts: Where, when, how much? ("Only on line 1, only in the early shift").
3. Match causes: Form hypotheses and check against the facts. ("Could it be the measuring device? No, because Skip 3 works.") This saves hours of pointless troubleshooting.

• Form fact pairs: The key is comparison: "What is the problem?" vs. "What is not the problem?" If the error only occurs on line 1, but line 2 is identical, it cannot be a general software problem.

• Documentation is not an end in itself: After the repair, it must be documented. But not for the file, rather for the next colleague. A photo of the defective cable and a short text ("Cable tie too tight") are often enough.

• Cultural change: Kai (participant) asked: "How do I get the 50-year-old maintenance worker not to immediately grab the screwdriver?" Answer: Lead by example and patience. You have to prove that the method is faster ("Those who think repair less").

Classification: Structured problem-solving with AI support

This episode shows that troubleshooting is a logic task. ADAM is the assistant that supports this logic.

• The digital notepad: David's "paper" is digital in ADAM. When the disruption is reported, ADAM automatically asks the W-questions ("Which line? Which product?"). So the facts are already there before the technician sets off.
• Hypothesis generator: Based on history, ADAM can make suggestions: "For this error pattern on line 1, it was the sensor X in 80% of cases." This massively accelerates hypothesis formation.
• Preserve knowledge: David says: "After the repair is before the repair." ADAM makes it easy for the technician to save the solution (take a photo, speak in). Next time, this solution pops up automatically ("Caution, do not tighten cable tie too much!").

Conclusion: Whether paper or app – the principle is the same: Think first, then screw. ADAM helps with thinking so that screwing goes faster.