HomeTechnical cornerTechnical cornerMachine breakdowns: cut diagnostic time by making the machine readable

Machine breakdowns: cut diagnostic time by making the machine readable

  • 12 May 2026
  • Posted by: Yann Chapron
  • Category: Technical corner
No Comments

Technical corner · Maintenance · 5 min read

When a machine stops, we think of the repair first. Yet in the field, the repair is often not what costs the most time: it is finding the cause. The technician arrives, reads an unclear fault message, opens the cabinet, tests the sensors one by one… Meanwhile, production is waiting.

The good news: this time can be reduced, often without a big investment. You just need to make the machine readable.

Anatomy of a machine stopIllustrative diagram: the length of each phase varies by machineDetectionalarm, stopFinding the causeoften the longest phaseRepairinterventionRestartcheck, restartThis is where a “readable” machine saves timeStatus on screeneach functionVisible safetywhich door, which E-stopStatus manualwhat the screen meansFault historymonthly Pareto

1. Show the status of each function

A screen that only says “Machine fault” forces people to search. A screen that shows the status of each function (waiting, running, done, faulty) shows immediately where the sequence stopped. It is the basis of fast diagnosis, for production as well as maintenance.

2. Make safety devices visible

A door not properly closed or an emergency stop pressed at the end of the line: a frequent and frustrating cause of stoppage. If the screen shows which door or which emergency stop is preventing start-up, the operator can often fix it without calling maintenance.

3. Fault messages that say what to do

“Fault 27” says nothing. “Transfer cylinder: forward limit not reached, check sensor B12 and air pressure” points straight to the right action. This work is done once, during programming, and pays off for the whole life of the machine.

4. A status manual and up-to-date diagrams

The screen does not replace documentation. A short manual explaining each status and each fault, and up-to-date electrical diagrams, let any technician, even one new to the machine, troubleshoot without depending on “the one who knows”.

5. Track faults to act on the right ones

Logging every stop with its cause, then producing a monthly Pareto (the few causes that account for most of the lost time), lets you focus effort where it pays off most.

Checklist: is your machine readable?The screen shows the status of each function (ready, running, faulty).A safety fault shows which door or emergency stop is involved.Each fault message says what to check, not just “Fault 27”.A manual explains statuses and faults, for all technicians.Electrical diagrams are up to date and available near the machine.Stops are logged and analysed every month (Pareto).Fewer than 4 boxes ticked? Your diagnostic time can probably drop significantly.

A real example

On the Biko unwinder at Elis Belgium, ITS replaced the PLC and the operator panel: each function and each door safety device is now shown on screen, and a maintenance manual explains every status. When the machine stops, the cause can be read directly on the screen.

Are your teams losing time finding the cause of stoppages? Let’s talk: a diagnosis of your machine shows what can be improved.