Playbooks/ Last updated: 2026-09-29

Playbook: a key machine breaks down mid-week

The situation

It is Tuesday morning. The spindle bearing on CNC-01 seizes during a roughing pass and the machine stops. A technician is on the way. Two questions matter more than the repair itself:

Which orders were running on this machine, and which customers are waiting for them?
Is this a one-off, or a machine that keeps failing?

This playbook answers both, then puts the repair on the calendar and re-plans the work.

The screenshots come from the Otiox demo workspace. To follow along, choose Switch to demo in the sidebar — changes there never touch your live data.

Step 1 — Log the breakdown

Go to Production → Planning → Machines, open the menu on the CNC Mill — CNC-01 card and choose Log Downtime.

Logging a breakdown on CNC-01 with its reason and impact

Set the type to Breakdown, keep the start time, and describe the reason and the impact — here, Signal Controller and Enclosure housings on hold until the spindle is replaced. Leave the end time empty while the machine is still down.

Step 2 — Take the machine offline

From the same menu choose Set Offline. The machine card now shows it as offline, so planners and the floor see it is down.

CNC-01 marked offline on the machines overview, with its upcoming maintenance

Step 3 — See the orders on the machine

Choose View Assigned Orders. Every manufacturing order assigned to CNC-01 is listed with its product, quantity and status.

Orders assigned to CNC-01: two manufacturing orders in progress

In the demo, two orders are in progress: MO-PRED-0001 (Signal Controller) and MO-PRED-0002 (Enclosure Assembly).

Step 4 — Follow the risk to the customer

Open Predictive Insights and choose Run prediction scan. Filter by Machine breakdown → production/SO at risk.

Breakdown risk on CNC-01, traced to two open manufacturing orders and two customer orders

The engine counts 4 stoppages in 30 days on CNC-01 and follows the chain: the machine → the 2 open manufacturing orders scheduled on it → the 2 sales orders that depend on them. Decision Synthesis recommends scheduling maintenance now, before the next breakdown stops those orders. Open machine takes you straight back to it.

One stoppage is an incident. Four in a month is a pattern — and the engine tells you which customers the pattern puts at risk.

Step 5 — Schedule the repair

From the machine menu choose Schedule Maintenance.

Scheduling a critical corrective repair on CNC-01 with the work required and a technician

Pick the date and an 8h window, set the type to Corrective / Repair and the priority to Critical, describe the issue and the work required, and assign the technician. If manufacturing orders are scheduled on the machine during that window, the dialog warns you — in the demo, *Machine busy: 2 order(s) scheduled during this time*.

The repair then appears under Upcoming Maintenance on the machines overview and in the maintenance calendar.

Step 6 — Re-plan the affected orders

Go to Planning → Schedule and filter All Machines to CNC-01.

The schedule filtered to CNC-01: both orders with their customer orders, flagged

Both orders are listed with the customer order they serve, their planned window and material status. Move them to another machine or a new date, and call the two customers with a date you can keep.

What you have at the end

The stoppage recorded with its reason and impact.

The orders and customers affected, found in minutes.
A breakdown pattern flagged before the next failure.
The repair on the calendar, planned around production.