What is the Fault-to-Fix Loop in manufacturing?
The Fault-to-Fix loop is the critical operational cycle that begins the millisecond a machine performance drop is detected and ends when the asset is returned to its rated Takt time, encompassing detection, notification, diagnosis, and repair execution.
In a siloed factory, this loop is broken by "Information Silos" and manual hand-offs.
Mike (the Tactical Manager) sees a red light on a dashboard but must manually find Tom (the Technician) to investigate.
Fabrico eliminates this friction by ensuring that every OEE performance threshold breach natively triggers a prioritized Work Order in a Field-Ready CMMS.
Decision Latency: The Silent Tax on Your Availability Score
What is the primary driver of high MTTR?
The primary driver of Mean Time to Repair (MTTR) is "Decision Latency"—the cumulative time wasted while supervisors check reports and manually assign tasks rather than using an automated System of Action to dispatch technicians.
For Paula (the Strategic Leader), this latency is a hidden financial tax that drains your Hidden Factory revenue.
In a high-speed bottling or packaging line, a 15-minute delay in technician response can cost $2,500 in lost output.
Fabrico closes this gap by sending smart notifications directly to Tom’s mobile device the second the PLC detects a cycle-time slowdown.
How Computer Vision Slashes Diagnostic Time
Diagnosis often accounts for 50% of your total downtime duration because technicians have to "guess" what happened during the failure.
Fabrico’s Inefficiencies Zoom-In (Computer Vision) module acts as a digital "Replay" for your maintenance team.
Instead of Tom guessing why a feeder jammed, he watches a 10-second video clip of the failure on his mobile device.
He sees the specific mechanical friction or material defect in real-time, allowing him to execute a permanent fix rather than a temporary adjustment.
Comparison Matrix: Fault-to-Fix Performance
| Capability |
Manual / Paper Systems |
Siled OEE Dashboards |
Fabrico (System of Action) |
| Fault Detection |
Human Observation |
Real-Time Data |
Instant / Millisecond |
| Response Trigger |
Radio / Phone Call |
Emailed Alert |
Automated Work Order |
| Root Cause Depth |
Subjective / Guessing |
Data-Only Logs |
Advanced (Visual Zoom-In) |
| Maintenance Link |
None |
Via API (Complex) |
Native Integrated CMMS |
| Decision Latency |
Very High (Days) |
Moderate (Hours) |
Zero (Automated) |
| ROI Strategy |
Survival |
Reporting |
Revenue Reclamation |
Lowering Your Maintenance Cost per Unit
Sustainable OEE growth requires moving away from the "Firefighting" culture that inflates your labor budget.
By closing the Fault-to-Fix loop, you move your team to Condition-Directed Tasks triggered by actual production performance.
This ensures your maintenance effort is always focused on the Value Fulcrum, the high-impact tasks that directly protect your revenue.
This shift reduces your Maintenance Cost per Unit and ensures your capital assets reach their full residual value without new Capex.
The Strategic Verdict: ROI is in the Velocity
For Paula, the business case for Fabrico is built on the speed of improvement.
By reclaiming the capacity lost to communication gaps and slow diagnostics, you effectively find "free" production time in your existing facility.
As the system builds 12 months of clean 3D data, it prepares the plant for the Fabrico Agent (AI Roadmap) to automate these cycles.
Stop measuring your downtime. Start engineering your uptime with a System of Action.
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