Maintenance Troubleshooting Training for Plant Managers

Your Break-Even

Run it on your plant's numbers.

Industry averages get discounted. Your own downtime log doesn't. Change any number below.

Example inputs Downtime cost per hour on your key lineLost output, labor, and scrap $ Controls breakdowns per monthElectrical or pneumatic Minutes faster per breakdownA conservative guess Contractor callouts avoided per yearControls faults only Cost per calloutFrom your invoices $

$31,500

estimated value per year from faster repairs and avoided callouts.

1.9 monthsEstimated payback on a $5,000 Facility License

20 minOf avoided downtime pays for the whole license

Starting smaller? 3 technicians is $1,191, about 5 minutes of downtime.

An estimate from your inputs, not a guarantee. The 90-day scorecard below is how you find out for real.

Why Training Gets Cut

Nobody gets credit for problems that never happened.

When budgets tighten, training and planned maintenance go first, because breakdowns still have to be fixed. For a few months the numbers look better. Then skills erode, breakdowns climb, and overtime and contractors fill the gap.

DuPont measured it in the early 1990s. After years of cuts it was spending 10 to 30% more on maintenance than industry leaders, with 10 to 15% less uptime. Plants that rebuilt capability cut direct maintenance costs by about 20%.

Your crew didn't get worse. The experienced people left, and the method left with them.

Source: Repenning and Sterman, MIT, California Management Review, 2001.

Illustrative shape only, not plotted data. Based on the dynamic described in the MIT research above.

The 90-Day Scorecard

See what changed. On your own faults.

Your maintenance manager records a baseline before the crew starts, then measures again at day 30, 60, and 90. You get the numbers, not a sales pitch.

What gets measured	Baseline	Day 30	Day 60	Day 90
Average time to diagnose an electrical fault
Average time to diagnose a pneumatic fault
Controls faults escalated to a supervisor
Contractor or OEM callouts for controls faults
Maintenance overtime hours
Repeat failures on the same asset

Included with the Facility License as a downloadable spreadsheet.

About 5 hours, total

67 short lessons your techs work through between work orders or on slow shifts. No week off-site.

No equipment down

Nothing comes off the line to train. The lessons run on the phones your techs already carry.

Scope, plainly

Troubleshooting of automation controls. Not PLC programming, and not electrical safety training. Keep your NFPA 70E and lockout programs.

Pricing

One facility. Your whole maintenance team.

Most plants Facility License

$5,000per facility

Every maintenance tech at one location on the same troubleshooting method, including the ones you hire this year.

Up to 25 technicians at one facility
Up to 5 admins for managers and supervisors
The 90-day scorecard and a setup call
Progress view and completion certificates
Pay by card, bank transfer, or invoice

Buy the Facility License

Prefer to talk first? Book a 30-minute call

Per Technician

$397per technician

Start with a few techs on a company card, and add more any time.

The full Fault Fixer course, all five modules
Their progress, visible to your team
Completion certificate
3 admin accounts

Enroll Technicians

13 or more techs? The Facility License costs less.

JS

Built by Jordon Schultz, an Air Force veteran who went from no controls background to coaching maintenance techs within six months. 700+ technicians trained since.

Before You Approve It

The questions plant managers ask

It's not in the budget.

You're likely already paying for the skills gap in contractor callouts, overtime, and downtime. Run the calculator above on those lines. If $5,000 is too much right now, start with a few techs at $397 each on a company card.

Show me the ROI.

Not with industry averages. Use your own numbers in the calculator, then let the 90-day scorecard measure repair time, callouts, and overtime on your actual faults.

We've bought training before and nothing changed.

Most programs fade. This one is about 5 hours, not a week off-site, the testing roadmaps get used on the floor as job aids, and the results are measured on your plant's faults rather than a survey.

What if we train them and they leave?

What if you don't, and they stay? Manufacturing techs stay longer than most workers, a median of about five years, and the Facility License covers the people you hire to replace anyone who leaves.

Our techs are experienced. They should already know this.

Experience and a repeatable method aren't the same thing. When your go-to controls tech is off shift, the method needs to live in everyone.

HR needs training records and certificates.

Every tech gets a completion certificate, and you can export each person's completion dates and progress for HR [confirm formats: CSV, PDF]. Talk to us about anything your HR team needs to import.

Our industry is different.

Sensors, relays, contactors, solenoids, and valves fail the same way on a sorter, a press line, a packaging line, or a bottling line. The method carries across equipment and industries.

Put It on Your Scorecard

Stop paying for the skills gap in overtime and callouts.

Buy the Facility License today, start with a few techs, or talk it through first.

Buy the Facility License Book a 30-Minute Call

Your maintenance manager sent you this. Here's the two-minute version, in dollars.