When the setup expert goes on holiday: Who knows the undocumented parameters?
Production & maintenance
An experienced setup engineer has adjusted the plant so that it runs stably despite old components. This fine-tuning is not documented anywhere in the operating manual. On the day he is absent, his successor tries to reconstruct the parameters from memory. Finding no written specification, he risks production downtime or scrap due to incorrect settings.
The loss of implicit experience held by setup experts regarding undocumented machine parameters leads to scrap during succession and requires relearning. When this knowledge is captured, the assistant asks for clarification if a connection is unclear and cites the source with the reference for every answer.
- MAINTENANCE
- KNOWLEDGE LOSS
- MACHINE PARAMETERS
- SUCCESSION
WHAT THE LOSS COSTSThe loss of this implicit knowledge leads to downtime and scrap, as new staff must painstakingly determine the specific, undocumented settings. This causes double work and delays commissioning.
Capture. Connect. Find.
- CAPTURE01PeopleKnowledge is captured via the channel the team already uses, such as a short voice message sent directly from the machine or a photo of the adjustment knobs. The assistant asks follow-up questions if the knowledge is only in someone's head or if the connection to other parameters is unclear, closing the gap immediately.
- CONNECT02Connectors & measurement dataExisting maintenance logs and technical drawings are treated as documents, photos, or videos, not just stored. Email inboxes with historical exchanges regarding the machine can be imported as .eml files to complete the context of the settings.
- GRAPH & OUTPUT03Colleagues & systemsColleagues retrieve the linked knowledge later via the chat channel. The assistant answers in the language of the query and cites the source with the reference, making it clear whether the information came from a voice message or an old log.
What it sounds like day to day.
A typical question from this situation, the assistant's follow-up and the answer with its reference — an example, not a transcript.
How did the previous setup engineer adjust the hydraulic pressure setpoints for the press at low ambient temperatures?
Do you mean the main press P-04 or the downstream line L-2?
The main press P-04.
For the main press P-04, the pressure was increased by 0.5 bar at temperatures below 10 degrees to compensate for the oil's viscosity behaviour. This adjustment was not documented in the plant manual but passed on verbally.
Reference: Voice message, Role: Setup Engineer, Timestamp: 14:32, Date: 12.03.2024Self-check — loads when visible.
What businesses in this industry ask.
How can I implement knowledge management in the company without requiring employees to write additional documentation?
Knowledge is captured via around 20 channels, with a focus on the channel the team already uses. This means voice messages, photos, or videos can be captured directly at the machine without any manual input effort.
What is the difference between simple maintenance documentation and intelligent knowledge storage?
Simple documentation often just lists what was done. An intelligent system understands documents, photos, and videos and links them. The assistant asks follow-up questions if knowledge is only in someone's head, ensuring that implicit experience is preserved.
How do I ensure my machine documentation stays up to date when parameters change?
Documents, photos, videos, and voice messages are understood, not just stored. If a parameter changes, this can be captured as a new voice message or an updated photo. The assistant links this to existing knowledge and highlights any contradictions.
Why is comprehensive maintenance documentation so important for succession?
Without documentation, the implicit knowledge of experienced staff is lost, leading to scrap and long onboarding times. Comprehensive documentation secures know-how, allowing successors to access the same information and settings.
Limits that apply — even when nobody asks.
- Explicio does not release work on the machine — that stays with the qualified person.
- Explicio does not control any machine and writes to no controller.
- Explicio does not assess who caused a fault.
The same question from two directions.
- Is knowledge of legacy circuits missing during the SCADA transition?
- Who knows the legacy circuitry when the experts are on leave?
- Is knowledge of the old machine's settings lost when staff retire?
- Is knowledge of the special parameters of your older machines being lost as your experts retire?
- Who knows the machine’s special parameters when the setup engineer is absent?
Does this exact knowledge island exist in your business too?
Test this scenario now for 30 days free of charge – one voice message is enough.
- Term
- 30 days from your first knowledge
- Cost
- 0 €
- Licence
- none — we bill the knowledge, not the seat