Defect & Breakdown Management
Defect identification, assessment, repair, and closeout for critical assets
Asset ManagementLead Time
78.5h
Cycle Time
6.5h
Wait Time
72.0h
PCE
7.6%
Stages
7
Bottleneck
Parts & Resource Sourcing
Value-Add vs Non-Value-Add
Value-Add (VA)
An activity is value-add if it meets all three criteria:
- The customer is willing to pay for it
- It transforms the product or service
- It is done right the first time
Examples: Assembly, diagnosis, treatment, coding, machining, testing
Non-Value-Add (NVA)
Activities that consume time or resources but don't add value from the customer's perspective:
- Waiting — queues, approvals, batching delays
- Transport — moving materials or information
- Motion — unnecessary movement of people
- Rework — correcting defects or errors
- Over-processing — doing more than required
Note: Some NVA is necessary (compliance, safety). Target unnecessary NVA first.
Process Timeline
Value-Add vs Non-Value-Add
Bottleneck Analysis
Stage Efficiency
| # | Stage | Cycle (h) | Wait (h) | VA | Resource | Defect % | Efficiency |
|---|---|---|---|---|---|---|---|
| 1 | Defect Reported | 0.25 | 1.0 | VA | Operator | 10.0% | 20.0% |
| 2 | Triage & Priority Setting | 0.25 | 2.0 | VA | Maintenance Planner | 12.0% | 11.1% |
| 3 | Root Cause Investigation | 1.5 | 8.0 | VA | Reliability Engineer | 15.0% | 15.8% |
| 4 | Parts & Resource Sourcing | 0.5 | 48.0 | NVA | Procurement | 8.0% | 1.0% |
| 5 | Repair Execution | 3.0 | 4.0 | VA | Maintenance Tech | 5.0% | 42.9% |
| 6 | Functional Test | 0.5 | 1.0 | VA | Maintenance Tech | 4.0% | 33.3% |
| 7 | Closeout & Documentation | 0.5 | 8.0 | VA | Planner | 6.0% | 5.9% |