Book companion resource · Worksheet

MTTR Analysis Worksheet

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Find the asset-failure-mode combinations driving your availability loss, diagnose what makes them slow, and track job plan and parts readiness for the top three.

Companion to: Fix the System, Chapter 23. Who uses it: the maintenance manager, planner, and reliability engineer. When to use: at the start of the Downtime Reduction playbook, then monthly until availability stabilizes above 97%.

Plant / Line: _______________________ Date: _______________________ Completed by: _______________________

PART 1 — Downtime Event Log (Last 6 Months)

Pull all unplanned downtime events. Record asset, failure mode, and total MTTR. Sort by total downtime hours contributed — not by frequency.

Event #	Date	Asset	Failure Mode	Start Time	End Time	MTTR (hrs)	Primary Delay Cause

Primary Delay Cause codes:

PRT — Waiting for parts
DX — Diagnosis / troubleshooting time (unclear failure mode)
SKL — Waiting for technician with specific skill
ACC — Access, permit, or LOTO delay
RWK — Rework from incorrect first repair

PART 2 — Top 3 Asset-Failure-Mode Combinations

Group events from Part 1 by asset-failure-mode combination. Calculate total downtime hours per combination. Rank and select the top 3.

Rank	Asset	Failure Mode	# of Events	Total Downtime Hours	Avg MTTR	Dominant Delay Code
1
2
3
4
5

Top 3 account for ______% of all downtime hours.

Focus the next 90 days on the top 3 only. Address 4 and 5 in the following quarter.

PART 3 — Job Plan Readiness Assessment

For each of the top 3 combinations, assess the current job plan state.

Combination 1: _______________________

Assessment Item	Status	Gap / Action
Job plan exists in CMMS	☐ Yes ☐ No ☐ Outdated
Step sequence matches actual repair method	☐ Yes ☐ No ☐ Unknown
Parts list complete with part numbers and quantities	☐ Yes ☐ No ☐ Partial
Time estimate reflects actual repair duration	☐ Yes ☐ No ☐ Unknown
"Most common errors" section included	☐ Yes ☐ No
LOTO / isolation procedure current	☐ Yes ☐ No ☐ Missing

Job plan action required: ☐ Write new ☐ Rewrite existing ☐ Minor update ☐ None

Combination 2: _______________________

Assessment Item	Status	Gap / Action
Job plan exists in CMMS	☐ Yes ☐ No ☐ Outdated
Step sequence matches actual repair method	☐ Yes ☐ No ☐ Unknown
Parts list complete with part numbers and quantities	☐ Yes ☐ No ☐ Partial
Time estimate reflects actual repair duration	☐ Yes ☐ No ☐ Unknown
"Most common errors" section included	☐ Yes ☐ No
LOTO / isolation procedure current	☐ Yes ☐ No ☐ Missing

Job plan action required: ☐ Write new ☐ Rewrite existing ☐ Minor update ☐ None

Combination 3: _______________________

Assessment Item	Status	Gap / Action
Job plan exists in CMMS	☐ Yes ☐ No ☐ Outdated
Step sequence matches actual repair method	☐ Yes ☐ No ☐ Unknown
Parts list complete with part numbers and quantities	☐ Yes ☐ No ☐ Partial
Time estimate reflects actual repair duration	☐ Yes ☐ No ☐ Unknown
"Most common errors" section included	☐ Yes ☐ No
LOTO / isolation procedure current	☐ Yes ☐ No ☐ Missing

Job plan action required: ☐ Write new ☐ Rewrite existing ☐ Minor update ☐ None

PART 4 — Parts Staging Readiness

For each of the top 3 combinations, verify parts staging.

Combination	Parts List Verified?	Parts in Dedicated Location?	Qty Sufficient for 1 Repair?
1:	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
2:	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No
3:	☐ Yes ☐ No	☐ Yes ☐ No	☐ Yes ☐ No

Rule: Parts for top failure scenarios must be in a dedicated, labeled location — not in the general storeroom requiring a pick list. Available without a retrieval process at any hour.

PART 5 — Technician Coverage Matrix

For each of the top 3 combinations, identify which technicians can execute the repair independently (not just assist).

Target: Minimum 2 technicians per shift who can execute the repair independently.

Combination	Day Shift	Afternoon Shift	Night Shift	Coverage Gap?
1:	Names:	Names:	Names:	☐ Yes ☐ No
2:	Names:	Names:	Names:	☐ Yes ☐ No
3:	Names:	Names:	Names:	☐ Yes ☐ No

For each coverage gap: identify the cross-training candidate and the target completion date.

Combination	Technician to Train	Trainer	Method	Target Date	Completed
			☐ Shadowed ☐ Executed with guide ☐ Executed independently		☐
			☐ Shadowed ☐ Executed with guide ☐ Executed independently		☐
			☐ Shadowed ☐ Executed with guide ☐ Executed independently		☐
			☐ Shadowed ☐ Executed with guide ☐ Executed independently		☐
			☐ Shadowed ☐ Executed with guide ☐ Executed independently		☐
			☐ Shadowed ☐ Executed with guide ☐ Executed independently		☐

Note: Training is complete when the technician executes the repair independently using the job plan. Shadowing alone does not count.

PART 6 — 90-Day Availability Tracker

Week	Scheduled Hours	Unplanned Downtime Hours	Availability %	Top Failure Mode This Week	MTTR
Week 1
Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
Week 9
Week 10
Week 11
Week 12
Week 13

Formula: Availability % = (Scheduled Hours − Unplanned Downtime Hours) ÷ Scheduled Hours × 100

Benchmarks:

Below 95%: Critical. Apply this playbook immediately. Segment by failure mode before any other action.
95–96.9%: Recovering. Identify remaining top failure-mode contributors and address in sequence.
97–98.4%: Target range. Focus on first-time fix rate and job plan coverage.
98.5%+: World-class. Sustain through job plan discipline and technician coverage maintenance.

From Fix the System by Ivan Getov. Companion to Chapter 23: Playbook 9 — Downtime Reduction. getov.xyz/toolkit/fix-the-system/ch23/mttr-analysis. Free. No email required.

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