Reduce downtime by recording the failure mode, duration, operating condition, response, and recurrence—not by relying on a universal capacity-loss percentage.
Replace “Machine Down” With an Event Record
“Machine down” describes the effect, not the cause. Capture the alarm, component, symptom, job, material, tool, shift, operating condition, and action taken when those details are available.
The first useful distinction is whether the machine could not run, should not run, or had no ready work. Those conditions point to different owners and responses.
Frequent Short Stops
Group events by observable failure mode and total their effect. A repeated interruption can deserve attention even when each occurrence is brief.
Rare High-Impact Failures
Review safety, quality risk, repair lead time, spare availability, and whether the affected asset controls customer completion.
Match the Response to the Evidence
Confirm the physical condition and operating context.
Protect people, product, and the next production decision.
Select maintenance, training, repair, or redesign based on the mode.
Check whether recurrence and production impact actually changed.