For controls, process, maintenance, automation, instrumentation, PLC, manufacturing, robotics, systems, mechatronics, and integration engineers and technicians, plus industrial mechanics and maintenance managers.
Root cause analysis · trained hands-on
Train the instinct that ends downtime.
Fault Finder Lab builds diagnostic skill on live simulations of real machine faults. Probe, rule out, and prove the root cause the way you would on the floor. For engineers, technicians, and the managers who hire and upskill them.
For technicians & engineers
Upskill yourself.
- Work faults on a live machine: probe, rule out, repair the cause, and run it clean.
- Five-minute lessons on the concepts that get misdiagnosed daily: NPN vs PNP, pressure vs flow.
- A competency record and a Fault Finder Academy certificate that show what you can diagnose.
For maintenance & engineering managers
Upskill your department.
- Metrics: misdiagnosis patterns, stall points, and each technician’s ramp to independent diagnosis. See the reporting ↓
- Set up your team and assign training in minutes, not quarters.
- A course built for your equipment, curated, extended, or with a new simulator.
- Downtime and OEE move when the first hour of a fault isn’t spent guessing.
For supervisors · competency reporting
Watch diagnosis become independent.
- Misdiagnosis patterns
- Stall points
- Attempt replays
- Trend charts
- Email digests
- CSV export
| Scenario | True cause | Diagnosed instead | Times | Techs |
|---|---|---|---|---|
| Case flap hangs at the plow | Vacuum cup split | Plow out of square | 7 | 4 |
| Conveyor stalls under load | Gearbox key sheared | VFD overload trip | 5 | 3 |
| Wash pump cavitates | Suction strainer blinded | Worn impeller | 3 | 2 |
Spec
Built like the production floor.
- Machines
- Live, interactive machine models — cartoning and pump lines — with real-world PLC logic.
- Controls & field devices
- Fuses · safety relay · SSR · PLS · MCR · VFD · HMI · schematics · multimeter probing.
- Fault domains
- Pneumatic · hydraulic · electrical (component and wire level) · mechanical · controls · safety devices.
- Live sims
- Follow clues on a live, running machine to the root cause of the fault.
- Lessons
- Short reads, deep practice. Understand key concepts, then experience them.
- Certification
- Fault Finder Academy: a certificate program earned by diagnosing.
Root cause analysis
Three moves, in order.
Gauge
Read what the machine is telling you before touching anything.
Localize
Rule causes in and out with the right probe at the right point.
Reason
Settle the root cause. Then fix it once, and prove it.