The moment a machine stops, report it against the asset and it becomes a numbered breakdown work order — technician assigned, downtime clock running from stop to restart, cause and action recorded, spares issued, and the maintenance history updated with photos. Emergency or planned, every stoppage is tracked, and every hour of downtime feeds MTTR and the breakdown dashboard.
However the breakdown is reported, the flow is the same — so downtime, cause and cost are always captured. New to computerised maintenance? Start with our guide, what is CMMS software?
When a machine goes down, it is reported against the specific asset in the machine master, not scribbled in a logbook. That turns a stoppage into a numbered breakdown work order carrying the machine, the problem, the priority and the emergency-versus-planned flag — so nothing is lost between the shop floor and the maintenance office, and every breakdown is tied to a real asset with a history you can open later.
Guessed downtime makes useless KPIs. On the live machine status board a supervisor uses Start/Stop Machine, Report Problem and selects a stoppage reason, so the clock runs from the exact moment the machine went down until it is running again. Those real timestamps become the breakdown maintenance hours behind downtime analysis, MTTR and availability — the machine tells the truth, not a memory at shift-end.
The repair itself is recorded on the work order: the cause of the breakdown, the action taken to fix it, and the spares issued against the job. Because the spare part list is maintained per asset, the technician draws the right parts, stock and ledger stay accurate, and the true cost of the breakdown — labour plus spares — lands against the machine, ready to compare in the dashboard.
Closing the breakdown work order isn't the end of the record — it's the start of the asset's memory. The maintenance history updates with the cause, action, downtime and photographs, so the next time that machine misbehaves the technician can read what happened before. And because every closed breakdown carries its downtime, the numbers roll straight into MTTR and the machine breakdown dashboard — recurring failures stop being a feeling and become a chart.
Every stoppage becomes a numbered breakdown work order against the asset, with problem, priority and the emergency-or-planned flag.
Downtime captured from the exact stop to the exact restart, with a stoppage reason — real breakdown maintenance hours, not estimates.
Assign the job to a technician who picks it up on the floor or on mobile — clear ownership on every breakdown, not "someone is on it".
Record what failed and what was done to fix it on the job card, building a searchable failure history against each machine.
Issue spares against the work order from the per-asset spare list, updating stock and ledger and costing the breakdown honestly.
Closed breakdowns plot MTTR over time, breakdown hours and downtime analysis — machine-wise — so the worst offenders are visible.
Most breakdown handling fails at capture — the machine is fixed, but the downtime, cause and cost vanish. Here is what changes.
When a machine stops, the operator or maintenance desk reports the breakdown against the asset from the machine master, and it becomes a numbered breakdown work order. A technician is assigned, downtime is captured from stop to restart, the cause and action taken are recorded, spares are issued against the job, and the work order is closed — updating the asset's maintenance history with photos. The same data feeds MTTR and the machine breakdown dashboard.
Downtime is captured as real start and stop times rather than a guessed duration. On the live machine status board a supervisor clicks Start/Stop Machine, Report Problem and picks a stoppage reason, so the clock runs from the moment the machine goes down until it is restarted. Those timestamps become the breakdown maintenance hours that roll into downtime analysis, MTTR and availability.
An emergency breakdown is an unplanned stoppage that needs immediate attention — it is reported, assigned and worked at once, and the downtime clock runs the whole time. A planned or deferred breakdown repair can be scheduled as a work order for the next window when it will not halt production. Both are tracked the same way, so the breakdown dashboard shows emergency versus planned work and their downtime side by side.
Yes. Spares consumed on a repair are issued against the breakdown work order, so the parts are booked to the specific asset and job. Because the spare part list is maintained per asset, the technician sees the right spares to draw, stock and ledger stay accurate, and the true cost of the breakdown — labour plus spares — is recorded against the machine.
Every closed breakdown work order carries its downtime, cause and action, so the machine breakdown dashboard can plot MTTR over time, breakdown maintenance hours and downtime analysis — overall and machine-wise. Recurring causes surface, ageing breakdowns are visible, and management review sees which assets are costing the most uptime. Fast Maintenance runs cloud or on-premise, for manufacturers of every kind, across India and worldwide.
Live demo on your own machines — report a breakdown, run the downtime clock, issue spares and close the job. Cloud or on-premise, no generic slideshow.
