Maintenance & Reliability Toolbox

Preview Cards

Here are the first 5 questions. Create a conversation to invite someone and discuss each card.

1. {"Title":"Downtime Taxonomy & 5‑Why Diagnosis Form","IntroductionHtml":"<p>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.</p><p>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.</p>","SubmitLabel":"Save Downtime Event","SuccessMessage":"Downtime event saved. Share results with your team and schedule follow-up if needed.","DataType":"downtime-diagnosis-v1","SchemaVersion":1,"Fields":[{"Key":"event_datetime","FieldType":"text","Label":"Event date & time","HelpText":"Use YYYY-MM-DD HH:MM (24h) or a short local format. Example: 2026-08-07 14:35.","Required":true},{"Key":"reporting_person","FieldType":"text","Label":"Reported by (name/role)","HelpText":"Name and role of the person reporting the event.","Required":true},{"Key":"equipment_id","FieldType":"text","Label":"Equipment / Line / Cell","HelpText":"Identifier, machine name, or line number where the event occurred.","Required":true},{"Key":"shift","FieldType":"select","Label":"Shift","HelpText":"Select the shift when the event began.","Options":[{"Value":"morning","Label":"Morning"},{"Value":"afternoon","Label":"Afternoon"},{"Value":"night","Label":"Night"},{"Value":"other","Label":"Other / Mixed"}]},{"Key":"downtime_planned","FieldType":"radio","Label":"Planned or unplanned?","HelpText":"Is this activity scheduled (e.g., planned maintenance) or an unplanned stoppage?","Options":[{"Value":"planned","Label":"Planned"},{"Value":"unplanned","Label":"Unplanned"}],"Required":true},{"Key":"classification","FieldType":"checkbox","Label":"Downtime classification (select all that apply)","HelpText":"Use the taxonomy to capture primary contributing areas. Pick multiple if needed.","Options":[{"Value":"power","Label":"Power / Utilities"},{"Value":"tooling","Label":"Tooling / Fixture"},{"Value":"material","Label":"Material shortage / quality"},{"Value":"process","Label":"Process / Setup / Changeover"},{"Value":"human","Label":"Human error / operator"},{"Value":"maintenance","Label":"Maintenance / mechanical"},{"Value":"quality","Label":"Quality hold / reject"},{"Value":"software","Label":"Control / software / network"},{"Value":"other","Label":"Other (specify below)"}]},{"Key":"classification_other","FieldType":"text","Label":"If 'Other', specify","HelpText":"Provide brief detail when Other is selected."},{"Key":"start_time","FieldType":"text","Label":"Start time","HelpText":"When the stoppage started. Use HH:MM or the same format as Event date & time.","Required":true},{"Key":"end_time","FieldType":"text","Label":"End time (if known)","HelpText":"Enter when production resumed. Leave blank if still down."},{"Key":"duration_minutes","FieldType":"number","Label":"Duration (minutes)","HelpText":"If known, enter total downtime in minutes. Otherwise leave blank; the team can update later."},{"Key":"initial_containment","FieldType":"textarea","Label":"Initial containment / immediate actions taken","HelpText":"What was done right away to stop the impact, protect quality, or restart production? Include who did it and when.","Required":true},{"Key":"production_impact","FieldType":"yesno","Label":"Production backlog or units lost?","HelpText":"Quick yes/no to capture whether output was lost. If yes, estimate below."},{"Key":"units_lost","FieldType":"number","Label":"Estimated units lost","HelpText":"Provide best estimate; enter 0 if none or unknown."},{"Key":"estimated_cost","FieldType":"number","Label":"Estimated cost impact (local currency)","HelpText":"Optional rough estimate of immediate cost impact (labour, scrap, downtime)."},{"Key":"why_1","FieldType":"textarea","Label":"Why #1 — What happened? (the observable event)","HelpText":"Start with the immediate cause or symptom. Phrase simply and factually.","Required":true},{"Key":"why_2","FieldType":"textarea","Label":"Why #2 — Why did that happen?","HelpText":"Ask why the first condition occurred. Keep asking 'Why?' to move toward a root cause.","Required":true},{"Key":"why_3","FieldType":"textarea","Label":"Why #3 — Why did that happen?","HelpText":"Keep the chain of cause-and-effect. Stop when you reach a systemic cause you can act on.","Required":true},{"Key":"why_4","FieldType":"textarea","Label":"Why #4 — Why did that happen?","HelpText":"Continue to probe deeper toward processes, systems, training, or design causes.","Required":true},{"Key":"why_5","FieldType":"textarea","Label":"Why #5 — Why did that happen?","HelpText":"If the fifth 'Why' reaches a clear actionable root cause, record it. If not, record the best explanation you have.","Required":true},{"Key":"root_cause_summary","FieldType":"textarea","Label":"Summary root cause (team consensus)","HelpText":"Write a short sentence summarizing the root cause the team agrees on.","Required":true},{"Key":"temporary_countermeasure","FieldType":"textarea","Label":"Temporary countermeasure (what we did to restart)","HelpText":"Describe short-term measures that got production moving. Note any risks or limitations.","Required":true},{"Key":"permanent_corrective_action","FieldType":"textarea","Label":"Proposed permanent corrective action(s)","HelpText":"Describe the longer-term fix(s) to prevent recurrence. Include scope and expected outcome.","Required":true},{"Key":"owner","FieldType":"text","Label":"Action owner for permanent corrective action","HelpText":"Name and role accountable for implementing the permanent action.","Required":true},{"Key":"due_date","FieldType":"text","Label":"Due date for permanent action","HelpText":"Use YYYY-MM-DD or a clear target date. If multiple actions, provide the earliest target date.","Required":true},{"Key":"priority","FieldType":"select","Label":"Priority for corrective action","HelpText":"Use priority to help planning and escalation.","Options":[{"Value":"low","Label":"Low"},{"Value":"medium","Label":"Medium"},{"Value":"high","Label":"High"},{"Value":"urgent","Label":"Urgent"}],"Required":true},{"Key":"follow_up_required","FieldType":"yesno","Label":"Follow-up required?","HelpText":"Will this need a verification or audit after the permanent action is implemented?"},{"Key":"follow_up_notes","FieldType":"textarea","Label":"Follow-up notes / verification plan","HelpText":"Describe how the team will verify the corrective action worked (measure, observation, sample size, date)."},{"Key":"lessons_learned","FieldType":"textarea","Label":"Lessons learned / coaching points","HelpText":"Short notes the team should share across shifts, cells, or similar equipment."},{"Key":"tags","FieldType":"text","Label":"Tags / keywords","HelpText":"Optional: add tags to help search and reporting (e.g., 'setup, bearing, supplier X')."}]}