Repeated problems are a serious concern for any manufacturing plant and need immediate attention of the engineering team. The concerns are - 1. Frequent down time drains limited resources 2. Frequent manpower deployment 3. Frequent use of spares adds to cost of maintaining a machine 4. Quality and production suffer and lower the production and increase rejections and cost Remedial actions - 1. Thoroughly understand the machine operation with production team 2. Understand the way of working of machine operator 3. Check what work was previously done by the maintenance team and how was it done 4. Check if all the correct spares were used 5. Check if work was done in the right way 6. Do CAPA or 5 Why analysis to solve the problem permanently

In case of recurring downtime incidents, first of all analyze the top factors contributing to 80% of the total down time through Pareto Chart. Then do 5 Why or Cause & Effect Analysis one by one with respect to 4Ms. TPM ( Total Productive Maintenance) or World Class Manufacturing technique should also applied.

Identify the real time problem done and Took CAPA. Finding the RCA analysis for the Down time. Down time Details get by 3M (Man, Machine,Method) If Man related downtime continues training given to operators. Autonomous maintenance done machine related. Operating process Method will educate operators for before stats the machine.

Recurring downtime indicates processes that are running out of control. This is most frequently the results of pushing a product into the factory without having the process engineers involved in the early stages of product development. Design for Manufacturing normally only given lip service when it should be an integral part of the product development cycle. The results are better products that cost less and higher efficiency factories. The development of the process must be concurrent with the product development. You not only do away with recurring downtime (efficiency increase) but the investment in co-development can cut your total time to market in many cases by 50%.