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Troubleshooting twins for manufacturing

Break it here.
Not on the floor.

Your next breakdown is coming. You just don't know when. Give your techs the machine, the fault and the meter now, so the real one is a repeat, not a first.

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CELL 2 · OPERATOR PANEL
⚠ ALARM · AXIS FOLLOWING ERROR
Cycle STOPPED
Motor temp HIGH
Noise High-pitch whine
Downtime 00:04:12 and counting
Unlock to lock out, meter it and find the cause

The problem

Every plant teaches troubleshooting the same way: on a broken machine, with the line down.

Training happens during downtime

The only time a new tech sees a fault is when it's costing you parts and hours.

Rare faults never get practiced

The once-a-year failure catches everyone cold, every year.

Know-how is retiring

Your best troubleshooters carry it in their heads. When they leave, it leaves with them.

Machine Trainer Studio lets your crew break it, fix it and do it again, as many times as it takes, without touching production.

A drill, start to finish

It plays like the real thing because it's wired like the real thing.
  1. The machine is running parts.Then a fault hits. Alarm on the HMI, red on the stack light, cycle stopped.
  2. Read what the machine is telling you.Compare what the PLC sees with what the field device is actually doing.
  3. Lock it out.Open the cabinet, panels and guards. Skip the lockout and the drill knows.
  4. Find it with the meter.Volts live, ohms dead. Ring out wires, test fuses, relays, valves and sensors.
  5. Fix only what's broken.Every unneeded part you swap costs you on the score.
  6. Prove it.Remove the lockout, restart, and make good parts again.
Downtime11:38
Wrong repairs1
LockoutDone
ResultFixed
Example score card. Every drill is logged to the tech's record.

What you unlock

A press brake cell in 3D next to its operator panel, alarms and output counters

Full machines, not videos

A live 3D machine, a working operator panel, real motion programs and a running PLC with every device wired to an address. Open the cabinet and it's all there.

Wiring view of a reversing starter panel with the meter reading +24 V DC between two terminals

Faults you can't safely stage

Blown fuses, broken cables, failed sensors, stuck valves, miswired motors. The kind of faults you'd never break on purpose on a real machine.

A drill in progress: an alarm, the operator report and a revealed guided step

Guided repair when they're stuck

New techs get walked from symptom to fix, step by step. Experienced techs go in blind and get scored.

Editing a machine cell layout with the parts library open

Scene builder

Build your own cell from a library of conveyors, sensors, robots, control panels, utilities and process equipment, then program it in Ladder, Function Block, Structured Text or Instruction List. Add scored drills to it if you want them.

Training records table listing date, trainee, scene, drill and score

Records your supervisor can use

Every drill, every score, every tech. See who's ready for the night shift alone, and export it to CSV.

Your machine, modeled

Any industrial equipment, not only CNC: a machine, a line, a control panel or a subsystem like a hydraulic unit. Send a functional brief: the equipment type, its axes, actuators or devices, the subsystems, and photos or sketches of how it works. We build an original functional redesign with your tags, your program and your faults, so your crew trains on how their machine actually works, and only your shop can see it. Have an OEM license that covers a digital twin? Ask for a licensed identical twin instead.

Machine trainers

The CNC tool grinder trainer in 3D with labeled sensors

CNC Tool Grinder

A 5-axis tool grinder with a tool designer, NC program, electrical cabinet and cell PLC.

Faults you'll chase
  • Servo running hot with a whine
  • Door interlock and safety relay faults
  • Air, coolant and drive problems
Full access
The robot weld cell trainer: a 6-axis robot inside a guarded cell

Robot Weld Cell

A 6-axis arc-weld robot on a two-station positioner, with teach-pendant programs, cell safety and a cell PLC.

Faults you'll chase
  • Cell safety and guarding trips
  • Robot-to-PLC handshake problems
  • Electrical and pneumatic faults
Full access
The cylindrical grinder trainer in 3D

Cylindrical Grinder

A CNC universal OD grinder with a part designer, NC program and cell PLC.

Faults you'll chase
  • Axis and spindle drive faults
  • Interlocks that won't make
  • Coolant, air and sensor failures
Full access

25 training scenes

From your first conveyor to a full panel build.
Bottling Line scene
Bottling Line
Laminating Line scene
Laminating Line
PLC Control Panel scene
PLC Control Panel
Machine Trainer Cell scene
Machine Trainer Cell
Basics4Panel & harness4Sorting & inspection3Material handling3 Robotics2Packaging2CNC & metalworking2Process & batch1 Converting & web1Extrusion1Molding & presses1Utilities1

Who it's for

Maintenance teams

Build real troubleshooting skill between breakdowns, not during them.

Training leads & supervisors

Run the same drill for every tech and see exactly who's ready.

Machine builders

Show buyers your machine before it's built, then hand it over as the training package.

How access works

  1. Pick a plan.
    Individual, site license, or a twin of your own machine, line, panel or subsystem: an original functional redesign, or a licensed identical twin if you hold the OEM license.
  2. Get your code.
    Emailed at checkout, or sent with your invoice.
  3. Everything opens.
    Every machine, drill and tool. Your shop's work stays private to your shop.

Practice the once-a-year fault today.

Your crew will meet it on the floor eventually. Let the first time be here.

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