Breakdown analysis poster

A breakdown that is repaired but not analysed usually comes back. Breakdown analysis is the short routine maintenance and operators run after each failure: record the facts while they are fresh, check whether the machine's basic conditions were met, find the root cause, fix that cause, check the same part on similar machines and update the standards. This poster sets out the seven steps for the maintenance board.

Download the poster

The PNG is free to download now. The print-ready vector PDFs open after a short form, once.

Download PNG (300 dpi)2550 x 3300 px, prints at 8.5 x 11 in · 405 KB · no form

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Breakdown analysis poster — 24 x 36 in18 x 24 inA2A3LetterA4PNG 300 dpi

The words on the poster

After a breakdown

Repair it, then make sure it cannot happen again.

Make safe and repair Lock out. Note what you find as you go.
Record the facts When, where, which part, how it failed. Keep the part, take photos.
Check basic conditions Was it clean, lubricated, tight, run within its limits?
Find the root cause Ask why at the machine until you reach a cause you can fix.
Fix the cause Not just the part: the method, the design or the standard.
Spread it Check the same part on similar machines.
Update the standards PM plan, CILR standard, spares list, notes for new equipment.

Repaired but not analysed? It will come back.

On the floor

How to use it

Putting the Breakdown analysis poster to work

1
Post it on the maintenance board and in the workshop where repairs are planned.
2
Agree which breakdowns get the full seven steps, such as every long stop on a critical machine.
3
Review open analyses in the weekly maintenance meeting, step by step.
4
Pair it with the free breakdown analysis report and machine history record.

Where the poster goes and how to teach with it, in the order to try them.

Which size to print

24 x 36 in or A2: a main wall or team board, read from a few metres away.
18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
Letter or A4: a clipboard, binder or handout, on any office printer.

Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.