Rapid downtime containment & root-cause playbook

{ "Title": "Rapid downtime containment & RCA form", "IntroductionHtml": "

Use this guided form during and after unplanned downtime events to contain hazards, collect evidence, run a rapid root-cause routine, and record verification and follow-up. Timebox immediate containment to on-shift responders (5–15 minutes). Complete the rapid RCA and plan short-cycle experiments during the improvement cycle rather than as a paper exercise.

Filling this form saves the event to the team log, helps huddles review, assigns ownership, and creates a repeatable record for learning and improvement.

", "SubmitLabel": "Save downtime event", "SuccessMessage": "Event saved. Share the form link with owners and include this item in the next huddle for review.", "DataType": "downtime_event_v1", "SchemaVersion": 1, "Fields": [ { "Key": "incident_id", "FieldType": "text", "Label": "Incident ID / Reference", "HelpText": "Use site numbering or create a short id (e.g., LINE3-2026-08-27-01)." }, { "Key": "event_datetime", "FieldType": "text", "Label": "Event date & time (local)", "HelpText": "ISO or readable format. Use the moment the fault was first observed." }, { "Key": "location", "FieldType": "text", "Label": "Location / Line / Cell", "HelpText": "Where did this occur?" }, { "Key": "equipment", "FieldType": "text", "Label": "Equipment / Asset", "HelpText": "Asset name, tag, or machine id." }, { "Key": "reported_by", "FieldType": "text", "Label": "Reported by (name/role)", "HelpText": "Who first reported or observed the event." }, { "Key": "immediate_containment", "FieldType": "checkbox", "Label": "Immediate containment checklist", "HelpText": "Check actions taken immediately to keep people safe and preserve production and evidence.", "Options": [ { "Value": "safety", "Label": "Secured safety / removed personnel risk" }, { "Value": "isolate", "Label": "Isolated energy / equipment (LOTO) as needed" }, { "Value": "stop_process", "Label": "Stopped process to prevent damage / scrap" }, { "Value": "recover_product", "Label": "Protected or recovered product in process" }, { "Value": "secure_evidence", "Label": "Preserved evidence (do not clear displays, take photos)" }, { "Value": "assign_owner", "Label": "Assigned on-shift owner / responder" }, { "Value": "notify_supervisor", "Label": "Notified supervisor / maintenance" }, { "Value": "log_start_time", "Label": "Logged start and containment times" } ] }, { "Key": "triage_type", "FieldType": "radio", "Label": "Triage classification", "HelpText": "Choose the best immediate classification to guide response.", "Options": [ { "Value": "repeat", "Label": "Repeat / known failure" }, { "Value": "random", "Label": "Random / intermittent" }, { "Value": "design", "Label": "Design / hardware defect" }, { "Value": "process", "Label": "Process or material related" }, { "Value": "unknown", "Label": "Unknown (needs investigation)" } ] }, { "Key": "containment_actions_taken", "FieldType": "textarea", "Label": "Containment actions - brief chronology with times", "HelpText": "Describe what was done, who did it, and the timestamps (e.g., 10:05 LOTO applied by Jake)." }, { "Key": "operator_notes", "FieldType": "textarea", "Label": "Operator & witness notes", "HelpText": "Operator observations, sensations, sounds, smells, alarms, recent changes." }, { "Key": "sensor_snapshot", "FieldType": "textarea", "Label": "Sensor / PLC snapshot or key readings", "HelpText": "Paste values, alerts, or short logs. If available, reference screenshots stored in your system." }, { "Key": "timestamps_and_media_refs", "FieldType": "textarea", "Label": "Timestamps and media references", "HelpText": "List file names, camera IDs, or folder locations for photos, videos, and logs." }, { "Key": "five_whys_1", "FieldType": "text", "Label": "Why #1 - What directly happened?", "HelpText": "Start with the immediate problem statement (the effect)." }, { "Key": "five_whys_2", "FieldType": "text", "Label": "Why #2", "HelpText": "Why did that happen?" }, { "Key": "five_whys_3", "FieldType": "text", "Label": "Why #3", "HelpText": "Why did that happen?" }, { "Key": "five_whys_4", "FieldType": "text", "Label": "Why #4", "HelpText": "Why did that happen?" }, { "Key": "five_whys_5", "FieldType": "text", "Label": "Why #5 (root cause hypothesis)", "HelpText": "State the likely root cause hypothesis. If there are multiple contributors, list them in order of confidence." }, { "Key": "fishbone_categories", "FieldType": "checkbox", "Label": "Fishbone categories checked", "HelpText": "Select categories to consider when expanding the root cause analysis.", "Options": [ { "Value": "machine", "Label": "Machine / equipment" }, { "Value": "method", "Label": "Method / procedure" }, { "Value": "material", "Label": "Material / supply" }, { "Value": "man", "Label": "People / staffing / skills" }, { "Value": "measurement", "Label": "Measurement / instrumentation" }, { "Value": "environment", "Label": "Environment / conditions" } ] }, { "Key": "fishbone_notes", "FieldType": "textarea", "Label": "Fishbone notes (evidence by category)", "HelpText": "For selected categories, capture the most convincing evidence supporting or refuting each possibility. Use short bullet points." }, { "Key": "rca_summary", "FieldType": "textarea", "Label": "Short RCA summary & primary countermeasure", "HelpText": "In one or two sentences, summarize the diagnosis and the primary countermeasure to test." }, { "Key": "cmms_work_order", "FieldType": "text", "Label": "Linked CMMS work order / ticket # (optional)", "HelpText": "Record the work order created for repairs or inspections." }, { "Key": "verification_test_steps", "FieldType": "textarea", "Label": "Verification & test steps", "HelpText": "Explicit steps to verify the fix with pass/fail criteria. Keep tests short and repeatable." }, { "Key": "handover_owner", "FieldType": "text", "Label": "Assigned owner for follow-up (name/role)", "HelpText": "Person accountable for follow-up experiments, CMMS tasks, and closure." }, { "Key": "closure_criteria", "FieldType": "textarea", "Label": "Closure criteria", "HelpText": "Conditions that must be met before the event can be closed. Be specific and measurable." }, { "Key": "closure_verified", "FieldType": "yesno", "Label": "Has verification passed?", "HelpText": "Mark yes when verification test steps succeed." }, { "Key": "follow_up_actions", "FieldType": "textarea", "Label": "Planned follow-up actions / experiments", "HelpText": "List short-cycle experiments, monitoring to run, expected durations, and success metrics." }, { "Key": "planned_test_date", "FieldType": "text", "Label": "Planned date for follow-up test", "HelpText": "When will the countermeasure be tested?" }, { "Key": "lessons_learned", "FieldType": "textarea", "Label": "Lessons learned & prevention ideas", "HelpText": "What will we change in standards, training, or design to prevent recurrence?" }, { "Key": "huddle_review", "FieldType": "yesno", "Label": "Include in next daily huddle review?", "HelpText": "Mark yes to add to the huddle agenda." } ] }