If a machine shows a recurring fault in the same subsystem, what action most directly follows?

• A. Reassign the operator
• B. Replace the entire machine
• C. Ignore the fault until it stops
• D. Modify the maintenance plan based on machine history

Answer: (D)

When a machine shows a fault repeatedly in the same subsystem, you should use that history to adjust how you maintain the machine. The most direct step is to modify the maintenance plan based on machine history. This means reviewing the fault data, performing a root cause analysis to understand why it keeps happening, and updating preventive maintenance tasks, inspection frequencies, parts replacement schedules, or calibration procedures for that subsystem. The aim is to prevent recurrence by tailoring maintenance activities to what the history shows about reliability and failure modes. Reassigning the operator doesn’t address the underlying issue, replacing the entire machine is typically unnecessary, and ignoring the fault is unsafe and could lead to bigger problems.