fault-case-report

name

fault-case-report

description

Generate comprehensive fault case reports after diagnostic completion. Use when a fault diagnosis has been completed and documentation is needed for knowledge retention, training, or archival purposes. This skill creates structured reports including fault manifestation, diagnostic trajectory, troubleshooting procedures, solutions implemented, fault tree analysis, and technical insights based entirely on conversation history.

Fault Case Report Generation Skill

Overview

Generate comprehensive, educational fault case reports that document the entire diagnostic process from initial symptoms to final resolution.

When to Use

• Fault diagnosis has been completed successfully
• Need to document lessons learned for future reference
• Creating training materials for maintenance teams
• Building knowledge base of resolved issues
• Reporting to management or technical review boards

Core Principles

No Fabrication Rule

CRITICAL: All report content must be based entirely on conversation history. Never invent:

• Measurements or data not provided by user
• Inspection results not confirmed
• Technical specifications not retrieved from verified sources
• Timeline events not documented

Educational Value Focus

Reports should serve as learning resources:

• Explain diagnostic reasoning clearly
• Highlight key decision points
• Document what worked and what didn't
• Provide preventive recommendations

Report Structure

1. Executive Summary

Brief overview containing:

• Equipment: Type, model, location
• Fault Summary: Primary symptom and impact
• Root Cause: Identified underlying issue
• Resolution: Solution implemented
• Timeline: Duration from report to resolution

2. Fault Manifestation

Detailed description of symptoms:

• Initial Report: User's original description
• Observed Phenomena: All symptoms noted during diagnosis
• Alarm Codes: Any error messages or alerts
• Operating Conditions: Context when fault occurred
• Impact Assessment: Effect on production/safety

3. Diagnostic Trajectory

Step-by-step timeline of the diagnostic process:

• Phase 1: Information Gathering - Questions asked, data collected
• Phase 2: Initial Assessment - Possible causes identified
• Phase 3: Systematic Testing - Each test performed and results
• Phase 4: Root Cause Confirmation - Final verification steps
• Decision Points: Key choices made and rationale

4. Troubleshooting Procedures

Detailed procedures that were executed:

• Inspection Steps: What was checked and how
• Measurements: Actual values obtained (with units)
• Standard Comparisons: Expected vs actual values
• Findings: What each test revealed
• Tools Used: Equipment utilized during diagnosis

5. Solution Implementation

Resolution details:

• Root Cause: Confirmed underlying problem
• Corrective Action: What was done to fix it
• Parts Replaced: Components changed (if any)
• Adjustments Made: Calibration or configuration changes
• Verification: How effectiveness was confirmed

6. Fault Tree Analysis (FTA)

Visual representation of diagnostic logic:

• Top Event: The reported fault
• Intermediate Events: Diagnostic decision points
• Basic Events: Individual tests and checks
• Logic Gates: AND/OR relationships
• Path Taken: Highlight the actual diagnostic path

Mermaid FTA Syntax:

graph TD
    A["Top Event: Fault Description"] --> B["Intermediate: Check 1"]
    A --> C["Intermediate: Check 2"]
    B --> D["Basic: Test A"]
    B --> E["Basic: Test B"]
    C --> F["Basic: Test C"]
    style A fill:#f96
    style D fill:#9f6

7. Technical Insights

Knowledge gained from this case:

• Diagnostic Logic: Why certain paths were chosen
• Key Indicators: Symptoms that pointed to root cause
• Distracting Factors: Red herrings or misleading symptoms
• Lessons Learned: What to do differently next time
• Preventive Measures: Recommendations to avoid recurrence

8. Appendices

Supporting documentation:

• Measurement Data Tables: Organized test results
• Technical References: Manuals, standards consulted
• Related Cases: Similar previous incidents
• Follow-up Actions: Scheduled monitoring or maintenance

Visual Elements

Required Graphics

1. Fault Tree Diagram: Mermaid flowchart of diagnostic process
2. Measurement Tables: Tabular comparison of actual vs standard values
3. Timeline Chart: Visual representation of diagnostic phases

Optional Graphics

• System diagrams showing component locations
• Before/after comparison charts
• Trend graphs if monitoring data available
• Photos of damaged components (if provided)

Quality Standards

Technical Accuracy

• All data verified against conversation history
• Units and measurements clearly stated
• Technical terms used correctly
• References cited properly

Completeness

• All diagnostic phases documented
• No gaps in the troubleshooting narrative
• Decision rationale explained
• Both successes and failures recorded

Clarity

• Logical flow from problem to solution
• Clear section headers and structure
• Visual aids support understanding
• Suitable for readers unfamiliar with the case

Examples

See examples/ directory for sample fault case reports:

• pump_bearing_failure.md: Complete bearing replacement case
• motor_misalignment_resolution.md: Alignment correction case
• valve_seat_erosion.md: Trim replacement case