Machine Downtime Communication Protocol

This protocol ensures every unplanned stoppage is captured, categorised, and escalated within prescribed timeframes. It standardises shift handover communication, embeds root‑cause codes in the CMMS, and links directly to MTTR / MTBF calculation rules. By enforcing a common language across operations and maintenance, the protocol eliminates conflicting priorities and delays that degrade OEE.

Applies to all production‑critical equipment (A‑ and B‑list assets) in the facility. Every downtime event exceeding 5 minutes must trigger the protocol. C‑list (non‑critical) assets follow a simplified version. The protocol involves operators, maintenance technicians, shift supervisors, and the reliability engineering team. Contractors working on site must also adhere to escalation rules.

• MTTRMean Time To Repair = Total downtime hours / Number of downtime events. Track from notification to verified restart. Target < 45 min for A‑list assets.
• MTBFMean Time Between Failures = Total operating hours / Number of failures. Excludes scheduled maintenance.
• DREDowntime Response Effectiveness = (Number of events escalated within 5 min / Total events) × 100. Minimum threshold: 90%.
• RCARoot‑Cause Categorization Rate = Downtime events with an assigned failure code / Total events × 100. Target 95% within 24 hours.

• Operator: Detect event, log time and initial cause category in CMMS within 2 minutes. Notify maintenance lead via radio / app.
• Maintenance Lead: Acknowledge within 5 minutes, assign technician, escalate to shift supervisor if downtime exceeds 20 minutes.
• Shift Supervisor: Approve overtime or contractor call‑in if required. Ensure handover communication at shift change includes unresolved downtime tickets.
• Reliability Engineer: Review weekly downtime data, recalculate MTTR/MTBF, update preventive maintenance plan and root‑cause library.
• Planner: Convert chronic failure codes into corrective work orders. Verify parts availability before scheduling repair tasks.