{"id":128139,"date":"2026-09-07T08:33:05","date_gmt":"2026-09-07T08:33:05","guid":{"rendered":"https:\/\/teeptrak.com\/?p=128139"},"modified":"2026-09-07T08:33:13","modified_gmt":"2026-09-07T08:33:13","slug":"downtime-reason-code-library-pareto-workbook","status":"publish","type":"post","link":"https:\/\/teeptrak.com\/en\/downtime-reason-code-library-pareto-workbook\/","title":{"rendered":"Downtime Reason-Code Library and Pareto Workbook: 56 Codes Mapped to the Six Big Losses (Excel + Field Guide)"},"content":{"rendered":"<p>Every plant has a downtime list. Most of them have two problems: too many codes for an operator to pick from in the 15 seconds before the machine restarts, and no rule for what a code means, so two shifts classify the same stop differently. The result is a Pareto whose top bar is &#8220;Other&#8221; and a maintenance team that does not trust the data. This pack gives you a starting tree that already respects the rules, the workbook to run it on, and the field guide that explains the rules.<\/p>\n<h2>What you get<\/h2>\n<ul>\n<li><strong>Reason-code library (Excel sheet):<\/strong> 9 categories (A equipment failure, B setup and adjustment, C minor stop, D reduced speed, E quality stop, F material flow, G organisation and people, H utilities and external, P planned downtime), 26 families, 56 level-3 codes. Each code carries its six-big-loss mapping, a planned flag, a counts-as-failure flag for MTBF, an owning function and a one-line &#8220;when to use&#8221;.<\/li>\n<li><strong>Data-field specification:<\/strong> the 17-field minimum record for one stop event, with type, required flag, rule and example, ready to hand to your MES or TEEPTRAK integrator. Seven fields are typed; the rest are derived.<\/li>\n<li><strong>Event log with dropdowns:<\/strong> machine, code and shift picked from lists; duration, category, big loss, planned and failure flags looked up automatically. 500 rows covered, 60 sample events included to see the Pareto work.<\/li>\n<li><strong>Self-updating Pareto:<\/strong> minutes and events per code, sorted automatically, cumulative share, the 80% cut, a bar and cumulative-line chart, plus Pareto by category and by machine with breakdown minutes, failures and MTTR per machine.<\/li>\n<li><strong>Six big losses summary:<\/strong> minutes and share of unplanned time per loss type, with the improvement lever for each.<\/li>\n<li><strong>Field guide (PDF, 4 pages):<\/strong> seven design rules, the stop record, capturing stops without slowing the line, reading the Pareto, governance cadence and tree versioning.<\/li>\n<\/ul>\n<h2>The tree at a glance<\/h2>\n<table>\n<thead>\n<tr>\n<th>Level 1<\/th>\n<th>Families<\/th>\n<th>Six big losses<\/th>\n<th>Counts in MTBF<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>A Equipment failure<\/td>\n<td>Mechanical, electrical \/ control, process equipment, unclassified<\/td>\n<td>Breakdowns<\/td>\n<td>yes<\/td>\n<\/tr>\n<tr>\n<td>B Setup and adjustment<\/td>\n<td>Changeover, adjustment, warm-up<\/td>\n<td>Setup and adjustments<\/td>\n<td>no<\/td>\n<\/tr>\n<tr>\n<td>C Minor stop<\/td>\n<td>Jam, sensor, cleaning, idle<\/td>\n<td>Idling and minor stops<\/td>\n<td>no<\/td>\n<\/tr>\n<tr>\n<td>D Reduced speed<\/td>\n<td>Speed loss, cycle loss<\/td>\n<td>Reduced speed<\/td>\n<td>no<\/td>\n<\/tr>\n<tr>\n<td>E Quality stop<\/td>\n<td>Defects, start-up loss, inspection<\/td>\n<td>Defects \/ start-up losses<\/td>\n<td>no<\/td>\n<\/tr>\n<tr>\n<td>F Material flow<\/td>\n<td>Starved, blocked, handling<\/td>\n<td>Idling and minor stops<\/td>\n<td>no<\/td>\n<\/tr>\n<tr>\n<td>G Organisation and people<\/td>\n<td>Operator, waiting, meeting \/ training<\/td>\n<td>Minor stops (waiting for maintenance: breakdowns)<\/td>\n<td>no<\/td>\n<\/tr>\n<tr>\n<td>H Utilities and external<\/td>\n<td>Utilities, IT \/ systems, external<\/td>\n<td>Breakdowns \/ minor stops<\/td>\n<td>no<\/td>\n<\/tr>\n<tr>\n<td>P Planned downtime<\/td>\n<td>Breaks, planned maintenance, cleaning, no order, trials<\/td>\n<td>Not an OEE loss<\/td>\n<td>no<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2>The seven rules the library is built on<\/h2>\n<ol>\n<li>Classify by cause, not by symptom: every level-3 code names something someone can fix, buy, train or reschedule.<\/li>\n<li>Three levels, no more. Four levels double the picking time and halve the classification rate.<\/li>\n<li>Separate planned from unplanned at level 1, or OEE and OOE become the same number.<\/li>\n<li>Each code carries its metadata; the operator never decides the big-loss mapping at the moment of the stop.<\/li>\n<li>Keep one &#8220;unknown&#8221; code and measure it. Above 10% of unplanned minutes, the list is too long or the capture too slow.<\/li>\n<li>Waiting is not repairing: log the response delay separately from the repair.<\/li>\n<li>Log every stop, including the short ones. A 5-minute threshold makes minor stops vanish into the performance rate.<\/li>\n<\/ol>\n<h2>Who this is for<\/h2>\n<p>Maintenance and production managers setting up or cleaning up a downtime classification, CI leads who need a Pareto they can defend in the weekly meeting, and teams specifying a machine-monitoring or MES project who need a reason-code standard before the vendor demo. It pairs with our <a href=\"https:\/\/teeptrak.com\/en\/free-downtime-tracking-template-excel\/\">downtime tracking template<\/a> and the <a href=\"https:\/\/teeptrak.com\/en\/free-mtbf-mttr-calculator-excel-template\/\">MTBF and MTTR calculator<\/a>.<\/p>\n<h2>Download the workbook and the field guide<\/h2>\n<p>Fill in the form and both files are sent to your e-mail address.<\/p>\n    <div class=\"teeptrak-form-container style-highlight\">\n        <h3 class=\"teeptrak-form-title\">Guided pilot<\/h3>                \n        <form id=\"teeptrak-6a9ea8cb3dda6\" class=\"teeptrak-form\" data-form-type=\"free_poc\">\n            <div style=\"position:absolute;left:-9999px;\"><input type=\"text\" name=\"website_url\" value=\"\" tabindex=\"-1\"><input type=\"text\" name=\"fax_number\" value=\"\" tabindex=\"-1\"><\/div>            \n            <div class=\"teeptrak-form-row teeptrak-form-row-half\">                <div class=\"teeptrak-form-field\">\n                    <label>First name <span class=\"required\">*<\/span><\/label>                    \n                                            <input type=\"text\" name=\"first_name\" required placeholder=\"\">\n                                    <\/div>\n                            <div class=\"teeptrak-form-field\">\n                    <label>Last name <span class=\"required\">*<\/span><\/label>                    \n                                            <input type=\"text\" name=\"last_name\" required placeholder=\"\">\n                                    <\/div>\n                            <div class=\"teeptrak-form-field\">\n                    <label>E-mail <span class=\"required\">*<\/span><\/label>                    \n                                            <input type=\"email\" name=\"email\" required placeholder=\"\">\n                                    <\/div>\n                            <div class=\"teeptrak-form-field\">\n                    <label>Phone <span class=\"required\">*<\/span><\/label>                    \n                                            <input type=\"tel\" name=\"phone\" required placeholder=\"\">\n                                    <\/div>\n                            <div class=\"teeptrak-form-field\">\n                    <label>Company <span class=\"required\">*<\/span><\/label>                    \n                                            <input type=\"text\" name=\"company\" required placeholder=\"\">\n                                    <\/div>\n                            <div class=\"teeptrak-form-field\">\n                    <label>Job title <span class=\"required\">*<\/span><\/label>                    \n                                            <input type=\"text\" name=\"job_title\" required placeholder=\"\">\n                                    <\/div>\n                            <div class=\"teeptrak-form-field\">\n                    <label>Production lines<\/label>                    \n                                            <select name=\"production_lines\" >\n                                                            <option value=\"\">Select<\/option>\n                                                            <option value=\"1-5\">1-5<\/option>\n                                                            <option value=\"6-20\">6-20<\/option>\n                                                            <option value=\"21-50\">21-50<\/option>\n                                                            <option value=\"50+\">50+<\/option>\n                                                    <\/select>\n                                    <\/div>\n                            <div class=\"teeptrak-form-field\">\n                    <label>Deadline<\/label>                    \n                                            <select name=\"timeline\" >\n                                                            <option value=\"\">Select<\/option>\n                                                            <option value=\"asap\">As soon as possible<\/option>\n                                                            <option value=\"1-month\">In 1 month<\/option>\n                                                            <option value=\"1-3-months\">In 1-3 months<\/option>\n                                                    <\/select>\n                                    <\/div>\n            <\/div>            \n            <input type=\"hidden\" name=\"page_url\" value=\"https:\/\/teeptrak.com\/en\/downtime-reason-code-library-pareto-workbook\/\">\n            <input type=\"hidden\" name=\"recaptcha_token\" value=\"\" class=\"teeptrak-recaptcha-token\">\n            \n                        \n            <div class=\"teeptrak-form-row\">\n                <button type=\"submit\" class=\"teeptrak-submit teeptrak-submit-full\">\n                    <span class=\"teeptrak-submit-text\">Request my POC<\/span>\n                    <span class=\"teeptrak-submit-loading\" style=\"display:none;\">Sending...<\/span>\n                <\/button>\n            <\/div>\n            \n            <div class=\"teeptrak-form-message\" style=\"display:none;\"><\/div>\n        <\/form>\n    <\/div>\n    \n<h2>From workbook to instrumented line<\/h2>\n<p>The workbook is the right tool to agree the tree and run the first Paretos on a few machines. It stops being the right tool when the number of stops per shift exceeds what an operator can type, which on a packaging line is usually within a week. <a href=\"https:\/\/teeptrak.com\/en\/downtime-tracking-software\/\">TEEPTRAK<\/a> captures every stop automatically from a sensor on the machine, without touching the PLC, prompts the operator for the code on a tablet at the machine, and rebuilds this Pareto in real time across all lines with the same tree. Across 450+ plants, the first effect is usually that the &#8220;minor stop&#8221; bar grows and the &#8220;unknown&#8221; bar shrinks: that is the data becoming true.<\/p>\n<p>Related reading: <a href=\"https:\/\/teeptrak.com\/en\/equipment-downtime-tracking\/\">equipment downtime tracking, a practical guide<\/a> and <a href=\"https:\/\/teeptrak.com\/en\/machine-downtime-tracking-software-comparison\/\">machine downtime tracking software comparison<\/a>.<\/p>\n<h2>Frequently asked questions<\/h2>\n<h3>How many downtime reason codes should a plant have?<\/h3>\n<p>Three levels and no more: a category the plant manager reads, a family the department head reads, and a reason the operator picks. The library ships 9 categories, 26 families and 56 codes. Machines should show a short list of their 8 to 12 most used codes first. Codes used fewer than 3 times a month get merged; codes above 15% of minutes get split.<\/p>\n<h3>How are the reason codes mapped to the six big losses?<\/h3>\n<p>Each code carries a six-big-loss attribute (breakdowns, setup and adjustments, idling and minor stops, reduced speed, defects and rework, start-up losses) plus a planned flag and a counts-as-failure flag for MTBF. The event log looks them up automatically from the code, so the operator never decides them at the moment of the stop.<\/p>\n<h3>How does the Pareto workbook update?<\/h3>\n<p>You log one row per stop in the Event log (machine, start, end, code). Duration, category, big loss and failure eligibility are computed. The Pareto sheet totals minutes and events per code, sorts them automatically, computes cumulative share and marks the 80% cut, and adds Paretos by category and by machine with MTTR per machine. Formulas cover 500 rows.<\/p>\n<h3>Why is waiting for maintenance a separate code from the breakdown?<\/h3>\n<p>Because MTTR should start at the stop, not when the technician arrives. The response delay is often the largest and cheapest part of repair time to reduce, and it disappears if it is folded into the breakdown code. The code G2.1 counts in the breakdown loss but not as a separate failure event in MTBF.<\/p>\n<p><script type=\"application\/ld+json\">{\"@context\": \"https:\/\/schema.org\", \"@type\": \"FAQPage\", \"mainEntity\": [{\"@type\": \"Question\", \"name\": \"How many downtime reason codes should a plant have?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"Three levels and no more: a category the plant manager reads, a family the department head reads, and a reason the operator picks. The library ships 9 categories, 26 families and 56 codes. Machines should show a short list of their 8 to 12 most used codes first. 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Most of them have two problems: too many codes for an operator to pick from in the 15 seconds before the machine restarts, and no rule for what a code means, so two shifts classify the same stop differently. The result is a Pareto whose top bar is &#8220;Other&#8221; [&hellip;]<\/p>\n","protected":false},"author":384731,"featured_media":0,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_yoast_wpseo_meta-robots-noindex":"","_yoast_wpseo_canonical":"","_et_pb_use_builder":"","_et_pb_old_content":"","_et_gb_content_width":"","ai_seo_title":"Downtime Reason Codes Library + Pareto Workbook (Free Excel + Guide) | TEEPTRAK","ai_meta_description":"56 downtime reason codes on 3 levels, mapped to the six big losses, with a stop-record spec, event log and self-updating Pareto workbook. Free Excel + guide.","ai_focus_keyword":"","footnotes":""},"categories":[129],"tags":[],"class_list":["post-128139","post","type-post","status-publish","format-standard","hentry","category-industrial-maintenance"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Downtime Reason Codes Library + Pareto Workbook (Free Excel + Guide) | TEEPTRAK<\/title>\n<meta name=\"description\" content=\"56 downtime reason codes on 3 levels, mapped to the six big losses, with a stop-record spec, event log and self-updating Pareto workbook. 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