CME388 INDUSTRIAL SAFETY

Dr. J. Allwyn Kingsly Gladston

Department of Mechanical Engineering
 UNIT – IV
FAULT TRACING
COURSE OBJECTIVES
4 To study the faults in various tools, equipments and machines.
OUTCOMES:
At the end of the course the students would be able to
4. Evaluate faults in various tools, equipments and machines
 UNIT – IV
FAULT TRACING
FAULT TRACING 9

Fault tracing-concept and importance, decision tree concept,

need and applications, sequence of fault-finding activities, show
as decision tree, draw decision tree for problems in machine
tools, hydraulic, pneumatic, automotive, thermal and electrical
equipment’s like, i. Any one machine tool, ii. Pump iii. Air
compressor, iv. Internal combustion engine, v. Boiler, vi.
Electrical motors, Types of faults in machine tools and their
general causes.
 SEQUENCE OF FUALT FINDING
ACTIVITIES
1. Symptom Recognition
Objective: Identify that something is wrong.
What happens:
User reports a malfunction.
System alarms or error messages are triggered.
Performance degradation is observed.
Tools:
Human observation
Monitoring software
Logs or dashboards
Example: A computer won’t boot, or an alarm sounds in an
 SEQUENCE OF FUALT FINDING
ACTIVITIES
2. Information Gathering
Objective: Collect relevant data about the fault.
What happens:
Ask users about the problem.
Review logs, system reports, or sensor data.
Check history of recent changes or maintenance.
Tools:
Event logs, test reports, diagnostic software
Interviews or operator notes
Example: Checking when the issue started, what software was
last updated, or what part failed previously.
 SEQUENCE OF FUALT FINDING
ACTIVITIES
3. Fault Verification (Reproduce the Problem)
Objective: Confirm the fault is real and reproducible.
What happens:
Attempt to reproduce the failure or symptoms.
Ensure it's not a user error or transient glitch.
Tools:
System simulation or reboot
Running diagnostic commands/tests
Example: Pressing the power button to confirm the device doesn't
respond.
 SEQUENCE OF FUALT FINDING
ACTIVITIES
4. Fault Localization (Narrowing Down)
Objective: Identify the subsystem or component where the fault
lies.
What happens:
Use decision trees or isolation techniques to eliminate
working parts.
Test subsystems one at a time.
Tools:
Multimeter, software debugger, fault tree analysis
Example: Determining whether a power failure is due to a faulty
power cord, supply unit, or internal motherboard issue.
 SEQUENCE OF FUALT FINDING
ACTIVITIES
5. Fault Diagnosis (Identify Root Cause)
Objective: Pinpoint the exact reason for the fault.
What happens:
Interpret data and test results.
Look for known failure patterns or common causes.
Tools:
Diagnostic trees
Expert systems or machine learning models
Example: Discovering a short circuit caused by a burnt-out
capacitor.
 SEQUENCE OF FUALT FINDING
ACTIVITIES
6. Fault Correction (Fix the Problem)
Objective: Apply the appropriate solution or repair.
What happens:
Replace, repair, or update the faulty component or code.
Tools:
Spare parts, patch management, repair kits
Example: Replacing a faulty RAM stick or applying a software
patch.
 SEQUENCE OF FUALT FINDING
ACTIVITIES
7. Verification of Repair
Objective: Ensure the fault is truly resolved.
What happens:
Re-test the system under normal conditions.
Confirm the original symptom is gone and no new issues arise.
Tools:
Functional testing, system monitoring
Example: Powering on the device to confirm it now boots
normally.
 SEQUENCE OF FUALT FINDING
ACTIVITIES
8. Root Cause Analysis (Post-Mortem)
Objective: Understand the underlying cause to prevent
recurrence.
What happens:
Analyze why the fault occurred.
Update maintenance procedures or design specs if needed.
Tools:
Fishbone (Ishikawa) diagrams, 5 Whys method
Example: Tracing a software crash to an unhandled exception in
legacy code.
 SEQUENCE OF FUALT FINDING
ACTIVITIES
9. Documentation and Reporting
Objective: Record the fault, actions taken, and outcome.
What happens:
Log the incident in maintenance records or software logs.
Share lessons learned or preventive actions.
Tools:
Maintenance logs, service management tools, CMMS
Example: Updating the ticket in an IT helpdesk system with full
resolution details.
 TYPES OF MACHINE TOOLS
1. Traditional (Conventional) Machine Tools
➤ Lathe
Used for turning, facing, threading, drilling.
Types: Engine lathe, turret lathe, CNC lathe.
➤ Milling Machine
Used to remove material using rotary cutters.
Types: Vertical milling, horizontal milling, universal milling, CNC
milling.
➤ Drilling Machine
Used for making round holes.
Types: Bench drill, radial drill, pillar drill, gang drill.
 TYPES OF MACHINE TOOLS
1. Traditional (Conventional) Machine Tools
➤ Shaper
Uses a linear tool to cut in straight strokes (reciprocating).
Best for flat surfaces and grooves.
➤ Slotter
Similar to a shaper but vertically oriented; used for keyways
and slots.
➤ Planer
Larger than a shaper; the workpiece moves while the tool is
stationary.
 TYPES OF MACHINE TOOLS
1.Traditional (Conventional) Machine Tools
➤ Grinding Machine
Used for precision surface finishing and cutting.
Types: Surface grinder, cylindrical grinder, centerless grinder,
tool and cutter grinder.
➤ Broaching Machine
Removes material with a toothed tool in a single pass.
Used for keyways, splines, and gears.
 TYPES OF MACHINE TOOLS
2. Advanced / CNC Machine Tools
➤ CNC Lathe
Computer-controlled lathe with precision turning.
➤ CNC Milling Machine
Multi-axis machine capable of precise milling, drilling, and
tapping.
➤ CNC Router
For softer materials like wood, foam, plastic, composites.
➤ CNC EDM (Electrical Discharge Machine)
Used for hard materials and intricate shapes.
Types: Wire EDM, sinker EDM.
 TYPES OF MACHINE TOOLS
2. Advanced / CNC Machine Tools
➤ CNC Plasma Cutter
For cutting metal using a plasma torch.
➤ CNC Laser Cutter
High-precision tool for cutting and engraving.
➤ CNC Water Jet Cutter
Uses high-pressure water (sometimes with abrasive) for
cutting.
 TYPES OF MACHINE TOOLS
3. Specialized Machine Tools 3. Specialized Machine
➤ Gear Hobbing Machine Tools

Used specifically for cutting gears. ➤ Turret Machine

➤ Honing Machine Allows multiple tools to

operate without
For improving surface finish and changing machines.
geometry.
➤ Lapping Machine
Used to produce fine, flat surfaces.
➤ Thread Rolling Machine
For forming threads without
cutting.
➤ Tapping Machine
 TYPES OF MACHINE TOOLS
4. Sheet Metal Working Machines
➤ Shearing Machine
Cuts large sheets into smaller pieces.
➤ Bending Machine (Press Brake)
Used to bend metal sheets into desired angles.
➤ Rolling Machine
Rolls sheets into cylindrical or curved forms.