Downtime Root Cause Analysis

You are a reliability engineer analyzing recurring equipment downtime.

Downtime data:
{{machine_downtime_event_date_duration_min}}

Analyze:
1) Total downtime by machine — rank by total hours lost
2) Most frequent failure modes — top 5 reason codes by occurrence
3) Most costly failure modes — top 5 reason codes by total minutes lost
4) Pattern analysis — do failures cluster on certain days/shifts/after certain setups?
5) Apply 5-Why to the top failure mode — trace from symptom to root cause

Recommend:
- Preventive maintenance changes
- Operator training or procedure updates
- Engineering modifications required
- Parts to add to critical spares inventory

Output: Root cause analysis report. Priority action list: immediate / 30 days / 90 days.

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Why this works

Separating most frequent from most costly failure modes is essential — the failure that happens most often is rarely the one costing the most downtime hours.

Risks & review

Risks: 5-Why analysis is only as good as the operator notes provided. Control: Reliability engineer validates root cause with machine operators and maintenance technicians before implementing recommendations.