Checklist

Downtime Taxonomy & 5‑Why Diagnosis Form

A structured form to classify downtime, capture immediate containment, and guide a 5‑Why root-cause conversation with action assignments.

Interactive Tool

Downtime Taxonomy & 5‑Why Diagnosis Form

Use this form at the line to capture an event quickly, classify the cause, record immediate containment, run a structured 5‑Why conversation, and assign temporary and permanent actions with clear ownership and due dates.

Fill what you know now; required fields are marked. This entry will be saved so the team can track follow-up and measure MTTR and repeat events.

Use YYYY-MM-DD HH:MM (24h) or a short local format. Example: 2026-08-07 14:35.
Name and role of the person reporting the event.
Identifier, machine name, or line number where the event occurred.
Select the shift when the event began.
Is this activity scheduled (e.g., planned maintenance) or an unplanned stoppage?
Use the taxonomy to capture primary contributing areas. Pick multiple if needed.
Provide brief detail when Other is selected.
When the stoppage started. Use HH:MM or the same format as Event date & time.
Enter when production resumed. Leave blank if still down.
If known, enter total downtime in minutes. Otherwise leave blank; the team can update later.
What was done right away to stop the impact, protect quality, or restart production? Include who did it and when.
Quick yes/no to capture whether output was lost. If yes, estimate below.
Provide best estimate; enter 0 if none or unknown.
Optional rough estimate of immediate cost impact (labour, scrap, downtime).
Start with the immediate cause or symptom. Phrase simply and factually.
Ask why the first condition occurred. Keep asking 'Why?' to move toward a root cause.
Keep the chain of cause-and-effect. Stop when you reach a systemic cause you can act on.
Continue to probe deeper toward processes, systems, training, or design causes.
If the fifth 'Why' reaches a clear actionable root cause, record it. If not, record the best explanation you have.
Write a short sentence summarizing the root cause the team agrees on.
Describe short-term measures that got production moving. Note any risks or limitations.
Describe the longer-term fix(s) to prevent recurrence. Include scope and expected outcome.
Name and role accountable for implementing the permanent action.
Use YYYY-MM-DD or a clear target date. If multiple actions, provide the earliest target date.
Use priority to help planning and escalation.
Will this need a verification or audit after the permanent action is implemented?
Describe how the team will verify the corrective action worked (measure, observation, sample size, date).
Short notes the team should share across shifts, cells, or similar equipment.
Optional: add tags to help search and reporting (e.g., 'setup, bearing, supplier X').
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