R.E.A.C.T. R: Recognize the issue E: Evaluate the situation A: Act to implement a temporary fix C: Communicate with maintenance or technical support T: Track the progress and resolution

Doing Quick Assessment and Diagnosis, Exert Backup Plans, Prioritize Critical Tasks, Communicate with Stakeholders, Engage Support and Resources, Monitor Progress and Adapt, Make Document and Learn

At the outset, we must and should ensure periodic maintenance to avoid unforeseen challenges, in case not able to perform in week days, must plan on Sundays, Holidays but under strict supervision. Over and above, critical equipments should be under strict watch of experienced persons during production to observe from close quarters. Focus should be to shift from reactive to planned maintenance using Predictive maintenance, condition based monitoring. Also we should have strategy to debottleneck machines by having alternates. Spares management keeping inventory in check and having VMI ie vendor managed inventory. Technical training to team at Gemba, based on skill matrix and Training Need Identification through OEM SMEs

Within the first 5 minutes everyone should recognize if it’s a show stopper, the next hour is tense triage where experience pays off. Faster the clean up, the better.

As you evaluating the breakdown and its impact on immediate production schedules, this is important to also understand any short term business or customer impact due to this situation and all options of utilising available inventory or product substitution have been optimised for the interim. If the machine downtime results in a real business loss, a thorough analysis of root cause should be done if the issue happened due to constrained capacity or excessive machine downtime resulted from avoidable maintenance issues.

In the face of adversity, it is imperative to conduct a thorough evaluation of the circumstances at hand, swiftly gauging the magnitude of the damage incurred and the anticipated duration required for restoration. To ensure continuity amidst disruption, it is essential to deploy contingency measures, utilizing alternative apparatus or resorting to manual methodologies that will preserve the flow of operations. Furthermore, maintaining transparent and effective communication is crucial; it is vital to keep all stakeholders apprised of any setbacks while articulating a comprehensive strategy for resolution, thereby fostering trust and collaboration during challenging times.

I would start by identifying the root cause through inspections and consultation with operators, using these tools for any analysis. Next, I would gather the team, including technicians and engineers, while ensuring clear communication. Preventive maintenance data would be leveraged to expedite the analysis process. If necessary implement a temporary or corrective solution to resume production while planning the permanent repair. Stakeholders would be kept informed about issues. After resolution, I would document the incident, actions performed, and lessons learned to prevent recurrence and optimize future processes. This is a crucial step in the process for fostering learning, increasing awareness, and improving mitigation strategies.

You should have the necessary spareparts and maintainance crew so that you can repair the machine in time for your deliveries. This is if you are a typical assembly or continuous production factory. It is different if you are a campaign factory. A campaign factory works with long production runs and long leadtimes because of the nature of the production process. Think of growing potatoes. You can't tell your potatoes to start growing in August. In such a company you have to solve your delivery problems by keeping stock and having excellent planning. Planning is even more important than production technology in such a case. You can have the most brilliant idea, if it is one day too late your turn will come next year...

In this situation, review the status of suppliers required to be made Vs schedule, maintenance engineers may review the status of machine & review the availability of key spares. If case extended hours maintenance activities are feasible, may be planned accordingly. Further, deep analysis is required to access the availability of contingency plan. Check if the preventive & predictive maintenance were ineffective. Ensure TPM - PM can be made more effective so that such situation never arise again.