Book companion resource · Worksheet
MTTR Clock Analysis Worksheet
Letter & A4. Print-ready. Free, no email required.
← Back to toolkit · Browse by chapterBreak repair events into clock components, identify the dominant delay, and track repair kit readiness and technician coverage for critical failure modes.
Companion to: Fix the System, Chapter 24. Who uses it: the maintenance manager, planner, and shift lead. When to use: at the start of the MTTR Reduction playbook, then monthly on any event exceeding 4 hours.
Plant / Asset Group: _______________________ Date: _______________________ Completed by: _______________________
PART 1 — Clock Breakdown: Last 5 High-MTTR Events
For each event, reconstruct the time sequence from failure notification to WO closure. Record each component in minutes.
| Event | Asset | Failure Mode | Response (min) | Diagnosis (min) | Parts Retrieval (min) | Repair (min) | Closure (min) | Total MTTR (min) |
|---|---|---|---|---|---|---|---|---|
| 1 | ||||||||
| 2 | ||||||||
| 3 | ||||||||
| 4 | ||||||||
| 5 | ||||||||
| Average |
Clock Component Definitions:
- Response — Failure notification (alarm, call, report) to technician physically on-site with WO.
- Diagnosis — Technician on-site to failure mode confirmed (root cause identified, repair scope defined).
- Parts Retrieval — Diagnosis complete to all required parts physically in hand at the job site.
- Repair — Parts in hand to asset restored and functional.
- Closure — Repair complete to WO closed in CMMS with all required information entered.
Dominant Component (highest average): _______________________
This is the first thing to fix. Do not address all components simultaneously.
PART 2 — Repair Kit Inventory
For each of the top 5 critical breakdown scenarios, assess the current repair kit state.
A repair kit is: a physical case or shelf section containing verified parts, specialized tools, the printed job plan, and the LOTO procedure for one specific breakdown scenario. Staged near the asset or in a designated emergency repair area. Not a CMMS parts list.
| Kit # | Asset | Failure Mode | Kit Exists? | Parts Verified (Physical)? | Job Plan Included? | LOTO Procedure Included? | Staged Location | Last Verified Date | Last Used / Restocked |
|---|---|---|---|---|---|---|---|---|---|
| 1 | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | |||||
| 2 | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | |||||
| 3 | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | |||||
| 4 | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | |||||
| 5 | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No | ☐ Yes ☐ No |
Rule: Parts in a kit must be physically verified — not confirmed from the CMMS. A kit built from a CMMS list that has not been physically checked may contain wrong specifications or missing items. Verify before sealing. Audit every 90 days.
Kits missing or incomplete: _______ Action owner: _______________________ Target completion: _______________________
PART 3 — Response Time and Escalation Protocol
Document the current response chain for each shift and verify it is functional.
Response Time Target: Technician on-site with WO and repair kit within _______ minutes of failure notification on critical assets.
| Shift | On-Call Technician | Contact Method | Response Time Standard | Escalation Contact (if no answer) | Escalation Method | Last Tested |
|---|---|---|---|---|---|---|
| Day | ☐ Phone ☐ Radio ☐ Pager | ___ min | ||||
| Afternoon | ☐ Phone ☐ Radio ☐ Pager | ___ min | ||||
| Night | ☐ Phone ☐ Radio ☐ Pager | ___ min | ||||
| Weekend Day | ☐ Phone ☐ Radio ☐ Pager | ___ min | ||||
| Weekend Night | ☐ Phone ☐ Radio ☐ Pager | ___ min |
Gaps identified: _______________________________________________
PART 4 — Diagnostic Aids Assessment
For each top failure mode, verify a one-page diagnostic aid exists.
A diagnostic aid is: a one-page fault tree or diagnostic sequence listing the three most likely causes in frequency order and the two-minute check that identifies each. Different from a job plan — the job plan tells you how to fix it; the diagnostic aid tells you what it is.
| Failure Mode | Asset | Diagnostic Aid Exists? | Last Updated | Cause 1 | Cause 2 | Cause 3 | Action if Missing |
|---|---|---|---|---|---|---|---|
| ☐ Yes ☐ No | |||||||
| ☐ Yes ☐ No | |||||||
| ☐ Yes ☐ No | |||||||
| ☐ Yes ☐ No | |||||||
| ☐ Yes ☐ No |
To write a diagnostic aid: Interview the most experienced technician for each failure mode. Ask: "When you hear this alarm / see this symptom, what's the first thing you check, and what are you looking for?" The three answers become the fault tree branches. Keep it to one page. Laminate it and store it in the repair kit.
PART 5 — Technician Coverage Matrix
Identify coverage gaps for each critical failure mode across shifts.
Target: Minimum 2 technicians per shift who can execute the repair independently (not just assist).
| Failure Mode | Asset | Day Shift | Afternoon | Night | Weekend | Gap Shifts | Cross-Train Plan |
|---|---|---|---|---|---|---|---|
Cross-training is complete when: the technician executes the repair independently using the job plan, with the experienced tech available but not directing. Document the date of independent completion below.
| Technician | Failure Mode | Completed Training Date | Independent Repair Date | Verified By |
|---|---|---|---|---|
PART 6 — Repair-vs-Replace Tracker
For assets with high repair frequency or cost, track cumulative two-year repair cost against replacement value.
Threshold: If 2-year accumulated repair cost exceeds 50% of replacement value, conduct a formal repair-vs-replace analysis.
| Asset | Replacement Value | Repair Events (2 yr) | Cumulative Repair Cost (2 yr) | Ratio (%) | Action |
|---|---|---|---|---|---|
| ☐ Continue repairing ☐ RVR analysis needed | |||||
| ☐ Continue repairing ☐ RVR analysis needed | |||||
| ☐ Continue repairing ☐ RVR analysis needed | |||||
| ☐ Continue repairing ☐ RVR analysis needed | |||||
| ☐ Continue repairing ☐ RVR analysis needed |
Note: The 50% threshold is a prompt for the conversation, not an automatic replacement decision. Factors that may justify continued repair: replacement lead time, capital budget cycle, production impact of extended changeover. Document the decision and rationale regardless of outcome.
PART 7 — 90-Day MTTR Tracker
| Week | Critical Asset Events | Total MTTR Hours | Avg MTTR (hrs) | Avg Parts Retrieval (min) | Avg Response Time (min) | Repair Kits Used | Kits Restocked? |
|---|---|---|---|---|---|---|---|
| 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 | ☐ |
Benchmarks:
- MTTR >8h: Action threshold. Build repair kits and break the clock immediately.
- MTTR 4–8h: Recovering. Identify dominant clock component and address.
- MTTR 2–4h: Target range. Focus on remaining parts retrieval and coverage gaps.
- MTTR <2h: World-class. Sustain through kit audits and coverage maintenance.
From Fix the System by Ivan Getov. Companion to Chapter 24: Playbook 10 — MTTR Reduction. getov.xyz/toolkit/fix-the-system/ch24/mttr-clock-analysis. Free. No email required.