Beyond the Text Log: Using Computer Vision 'Replay' to Master Root Cause Analysis

Every maintenance manager knows the sinking feeling of reading a Work Order request that simply says: "Machine stopped. Again."

You send a technician to the line. They jog the machine. It runs fine.

They stare at the PLC logs, which perhaps show a generic "Servo Fault." They ask the operator, who shrugs and says, "It just quit."

The technician marks the work order as "Could Not Duplicate" and closes it.

Two hours later, it happens again.

This cycle is the "Hidden Factory" at its worst. It kills your OEE (Overall Equipment Effectiveness) and drives up your MTTR (Mean Time To Repair). The problem isn't the machine; the problem is the lack of context.

Legacy CMMS platforms rely on text—typed by busy operators or auto-generated by cryptic PLC codes.

Fabrico changes the physics of troubleshooting by introducing Visual Root Cause Analysis.

What is Visual Root Cause Analysis?

Visual Root Cause Analysis is the integration of video capture technology with maintenance management systems to provide objective evidence of failure events.

Instead of relying on manual descriptions, the system automatically records and saves a video clip of the moments leading up to a downtime event, allowing technicians to "replay" the failure to identify the exact physical cause.

The Problem: Why Text Logs Lie (Or Leave Out the Truth)

In a high-speed manufacturing environment, operators prioritize restarting production, not writing detailed essays for the maintenance team. This leads to three distinct data gaps:

1. The Context Gap: A PLC can tell you that a motor overloaded, but it cannot tell you why. Did a package enter sideways? Was there a jam upstream? Did the operator intervene manually?

2. The "Ghost" Stop: Micro-stops (stops under 2 minutes) are rarely logged in a CMMS. Yet, if a machine stops 50 times a day for 30 seconds, you’ve lost 25 minutes of production—and you have zero data on why.

3. The "No Fault Found" Loop: If a technician cannot replicate the issue, they cannot fix it. This leads to parts changing (shotgun troubleshooting) without solving the root cause.

The Solution: The "Inefficiencies Zoom-In" Workflow

Fabrico bridges the gap between the System of Record (what happened) and the System of Action (how to fix it) by embedding Computer Vision directly into the maintenance workflow.

Here is how the "Zoom-In" feature transforms a breakdown response:

1. The Trigger

The machine experiences a micro-stop or a fault. Fabrico’s Unified Data Intelligence engine detects this signal from the PLC or the Computer Vision sensor itself.

2. The Capture

The system automatically saves a video clip of the event—capturing the 30 seconds before the stop and the moments immediately after. This is crucial because the cause of a jam usually happens seconds before the sensor trips.

3. The Assignment

A Work Order or "Check" task is generated in the Fabrico Field-Ready App.

4. The Diagnosis

Instead of walking to the machine blind, Tom (the Technician) opens the Fabrico app on his tablet. He clicks the event and watches the replay.

• He sees the package twist 45 degrees before hitting the guide rail.

• He sees the guide rail vibrate loose just before the impact.

Result: Tom doesn't waste 30 minutes testing sensors. He grabs a wrench, tightens the guide rail, and adds a "Check Guide Rail Alignment" task to the weekly PM schedule.

Comparison: Fabrico vs. The "Blind" CMMS

Why can’t you just install a CCTV camera? Because watching 8 hours of footage to find a 30-second glitch is impossible. You need a system that triggers on the event and links it to the repair.

The Financial Impact: From "Ghost" Stops to Revenue

For Paula (the Strategic Leader), this isn't just about making Tom’s job easier. It’s about the P&L.

If your line runs at 100 units per minute, and you profit 

500 per shift**. Over a year (3 shifts, 300 days), that one unsolved issue costs $450,000.

By using Fabrico to identify the root cause visually, you eliminate that recurring loss permanently. This is the difference between treating the symptom (resetting the machine) and curing the disease (fixing the mechanical flaw).

Summary: Stop Guessing, Start Seeing

Legacy maintenance relies on hearsay. Modern maintenance relies on evidence.

Fabrico is the only platform that combines the diagnostic power of Computer Vision with the execution power of a CMMS.

We don't just tell you OEE is low; we show you the video clip of why it's low, and then we give you the tools to assign the fix immediately.

Stop settling for "Could Not Duplicate."