Equipment Reliability &
Downtime Analysis
A reliability system that replaced inconsistent downtime inputs with structured operator data, recurring-failure analysis, and a clearer view of where maintenance attention was needed.
Existing reports showed downtime, but offered limited insight into recurring causes.
Downtime was already being reported, but the machine-generated logs relied on inaccurate inputs and were condensed into basic daily graphs. With four production units more than 50 years old, equipment issues were common, but it was difficult to separate recurring problems from one-off failures.
I started with the input. Operators recorded downtime in a simple weekly tracker using standardized codes, duration, and notes. I then translated those observations into a structured dataset with production impact, failure category, failure mode, root cause, maintenance action, and operator context.
The dashboard was useful because the collection process underneath it became more consistent.
Keep data entry simple where the downtime actually happens.
The operator-facing form stays intentionally lightweight: time, code, duration, and notes.
A shared code reference reduces variation in how common downtime events are described.
Notes capture what the operator saw so the structured record does not lose the frontline observation.
The operator entry becomes a record that can be compared over time.
The same structure supports an overall Pareto across all units and separate analysis for each primary asset.
One view for scale, frequency, and recurring failure patterns.
This portfolio workbook uses synthetic downtime records and generic equipment names. The layout and analysis model reflect the original system without exposing employer data.
The dashboard also breaks downtime into Pareto views so the largest recurring contributors are visible at a glance.
The live system includes an overall Pareto and separate Pareto analysis for each primary unit. The values above are synthetic portfolio data.
Values shown in this section come from the synthetic portfolio demo, not the live production dataset.
The data challenged an assumption about where recurring downtime was coming from.
Analysis connects directly to corrective action and problem solving.
The system is used in a weekly review with operations, maintenance, facilities, and site leadership. Findings have supported equipment repairs, longer-term vendor and rebuild discussions, and capital-spending justification.
The model expanded beyond the work area where it started.
The original system is updated weekly from operator inputs and can be maintained by a supervisor, lead, or operations/process co-op. A second work area adopted the same approach for its own equipment downtime.
Equipment Reliability & Downtime Analysis
Download the working Excel portfolio demo with a synthetic downtime log, dashboard, Pareto analysis, RAIL action tracking, and A3 problem-solving template.