A five-phase diagnostic worksheet for any equipment fault. Fill in each phase before moving to the next. Print one copy per fault event.
Complete before starting any diagnostic work. This information provides context for every subsequent phase.
Document exactly what happened, when, and under what conditions. Do not start testing until this phase is complete.
Collect objective data before forming hypotheses. Check all that apply and record measurements.
List all plausible causes, then rank by likelihood using the evidence above. Do not filter at this stage.
| Possible Cause | Supporting Evidence | Test Required | Rank |
|---|---|---|---|
Test one hypothesis at a time, starting with Rank 1. Document each test and result before proceeding.
| # | Test Performed | Expected Result (if cause is correct) | Actual Result | Outcome |
|---|---|---|---|---|
| 1 | ||||
| 2 | ||||
| 3 | ||||
| 4 | ||||
| 5 |
Do not close the work order until confirmation is complete and root cause is documented.
The complete system includes decision trees for 10 fault classes, failure mode documentation templates, worked examples across electrical, mechanical, and control system faults, and a 30-day team implementation guide.
For teams serious about reducing repeat failures and building transferable diagnostic knowledge.
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