03 PM - Step2 - EN - r1

MANUFACTURING
TRAINING
UNIT
Professional Maintenance
Step 2 – Breakdown Analysis
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The 7 steps of Professional Maintenance

Maintenance cost
management
Establishment of a planned
Step 7 maintenance system
Step 6 Build a predictive maintenance

system (trend management)
(CBM)
Step 5 Build a periodic maintenance system

Preliminary (TBM)
activities
Step 4 Countermeasures against weak points of the

machine and lengthened equipment life
Step 0
Step 3 Establishment of maintenance standards
Step 2 Reverse deterioration (breakdown analysis)
Elimination and prevention

Step 1 of accelerated deterioration
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MANUFACTURING
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TARGETS
• Prevent the recurrence of breakdowns in order to improve the
process performance
• Develop problem solving and breakdown analysis techniques
• Reduce the defective products due to the technical conditions of
the equipment
ACTIVITIES
• Define a system to record and analyze the breakdowns
• Collect, label and analyze the damaged components
• Find the root causes of breakdowns
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1. Breakdown analysis
Step 2
Breakdown Analysis
Why does the breakdown analysis?
The analysis is carried out to reduce the number of breakdowns,

preventing their recurrence and improving the process
performance degraded by losses due to breakdowns.
A breakdown, usually, means a sporadic event whose

characteristics are:
• Root cause “easy” to identify
• Countermeasures easy to implement
• Usual recovery way
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Step 2
Maintenance is measured on the capacity to respond and repair Breakdown Analysis
facilities necessary for production.
The effectiveness is measured not only by the repairing but also by:
• waiting time between breakdown and intervention
• repair time
• analysis of breakdown data
To manage breakdowns it needs to define a clear and shared

management flow. This flow supports standardized and systematic
recording of breakdown data.
Maintainers must be properly trained on the right flow management

and recording of events.
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The failure must be analyzed with different problem solving techniques Step 2
depending on the type and complexity of problem. Breakdown Analysis
Several problem solving techniques will need different skills, different actors
and different time for the identification and implementation of the
countermeasures.
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2. Emergency Work Order - EWO

Step 2
Breakdown Analysis
Equipment description
MTTR deployment
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Step 2
Breakdown Analysis
Breakdown intervention
description
Possible sketch of the problem
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Step 2
5W+1H Analysis
Breakdown Analysis
WHAT?
• On which machine/product did the
problem occurs?
• What material was used?
• Which dimension?
WHEN?
• Does it happen sporadically or
continuously?
• Was it in the start-up?
• Before or after a tool change?
• Does it happened in a specific time?
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Step 2
5W+1H Analysis Breakdown Analysis
WHERE?
• Where the anomaly occurred (line,
machine, robot…)?
• On which part did the problem occur?
• Where was the problem physically
highlighted?
WHO?
• Who found this problem?
• Only few operators have this problem?
• Does the problem is related to specific
skills?
• Only in some shifts does it occur?
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Step 2
5W+1H Analysis Breakdown Analysis
WHICH?
• Which features are related to the problem?
• Which trends or sequences have the
problem?
• Does the problem happen at random or is
related to something?
• Does the problem happen in a particular
condition?
HOW (come)?
• How did the anomaly occur?
• How is the actual state of the machine
compared to its standard operating
conditions?
• How often does the problem happen (hourly,
per shift, daily, monthly)?
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Step 2
Breakdown Analysis
List of possibile causes
Check of possible causes
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Step 2
Breakdown Analysis
5 why Analysis
Type of root cause
Suggestions for actions

to maintain
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Step 2
Breakdown Analysis
Actions against the root cause
Actions to maintain
(countermeasure standardization)
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Step 2
B/D
Breakdown Analysis
Insufficient
Excessive Deterioration
strenght
stress
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Step 2
B/D
Breakdown Analysis
Insufficient Excessive
Deterioration
strenght stress
Failure to
External Insufficient Design Lack of Lack of basic
respect oper.
influences skills weakness maintenance condition
conditions
AM standard
OPL for operators
or maintenance OPL for operating
PM calendar conditions
Skills map
Segnalazioni al Design std
fornitore/ente review
PD EEM PM PD AM
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2a. Root causes vs types of breakdowns

Step 2
Breakdown Analysis
casuali
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2a. Root causes vs types of breakdowns

Step 2
Breakdown Analysis
• Design weaknesses
Problems due
• Manufacturing errors
to lack of PM
• Installation errors
• Poor maintenance
• Supplier’s quality
problems
Human errors
(operator) like:
• AM not carried out
• Wrong conduction
• SOP not carried
out
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3. Breakdown Map and breakdowns stratification

Step 2
Example1
Breakdown Analysis
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Step 2
Example 2
Breakdown Analysis
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Step 2
Breakdown Analysis
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Step 2 certification
Step 2
At the end of the step should be
certify that the activities are Breakdown Analysis
carried out in the right way through

the application of a checklist.
The certification activity must be

carried out by the entire team of
PM:
• PM Pillar Leader
• Unit Managers
• PD Pillar Leader
• CD Leader
• FI Pillar Leader
• AM Leader
• WCM Plant Support
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MANUFACTURING

The 7 steps of Professional Maintenance

Step 6 Build a predictive maintenance

Step 5 Build a periodic maintenance system

Step 4 Countermeasures against weak points of the

Step 2 Reverse deterioration (breakdown analysis)

Elimination and prevention

The analysis is carried out to reduce the number of breakdowns,

A breakdown, usually, means a sporadic event whose

Maintenance is measured on the capacity to respond and repair Breakdown Analysis

facilities necessary for production.

To manage breakdowns it needs to define a clear and shared

Maintainers must be properly trained on the right flow management

depending on the type and complexity of problem. Breakdown Analysis

2. Emergency Work Order - EWO

2. Emergency Work Order - EWO

Possible sketch of the problem

2. Emergency Work Order - EWO

2. Emergency Work Order - EWO

5W+1H Analysis Breakdown Analysis

2. Emergency Work Order - EWO

5W+1H Analysis Breakdown Analysis

2. Emergency Work Order - EWO

Check of possible causes

2. Emergency Work Order - EWO

Type of root cause

Suggestions for actions

2. Emergency Work Order - EWO

Actions against the root cause

2. Emergency Work Order - EWO

2. Emergency Work Order - EWO

2a. Root causes vs types of breakdowns

2a. Root causes vs types of breakdowns

3. Breakdown Map and breakdowns stratification

3. Breakdown Map and breakdowns stratification

3. Breakdown Map and breakdowns stratification

carried out in the right way through

The certification activity must be

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