# Failed Component Teardown Inspection Report Template

> Source: https://netray.co/tools/failed-component-teardown-inspection-report-template
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

A fill-in report for post-failure teardown: what was found, failure mode, probable cause, whether the condition monitoring warning was correct and what changes.

## Category

maintenance

## Industry

Manufacturing

## Audience

- Reliability engineer
- Maintenance supervisor
- Mechanical technician

## Tool

**Kind:** template

**Output:** document

**Fields:**

#### Site or company

**Key:** company

**Type:** text

**Default:** Riverside Plastics

#### Asset and component

**Key:** asset

**Type:** text

**Default:** EXT-02 Extruder gearbox, output shaft bearing

#### Work order number

**Key:** wo

**Type:** text

**Default:** WO-558214

#### Teardown date

**Key:** date

**Type:** date

**Default:** 2026-10-16

#### Inspected by

**Key:** inspector

**Type:** text

**Default:** L. Haddad

#### Operating hours since installation

**Key:** hours

**Type:** text

**Default:** 14,200 hours

#### Condition monitoring warning before failure

**Key:** warning

**Type:** textarea

**Default:** Vibration envelope alarm raised 6 weeks before removal, ultrasound rise of 15 dB at last route.

#### Condition as found

**Key:** condition

**Type:** textarea

**Default:** Outer race spalling over about 25% of the load zone, grease dark and dry, cage worn at one pocket.

#### Failure mode

**Key:** mode

**Type:** select

**Options:**

- Fatigue spalling
- Lubrication starvation
- Contamination wear
- Misalignment or overload
- Electrical fluting
- Corrosion
- Installation damage
- Other

**Default:** Lubrication starvation

#### Probable root cause

**Key:** cause

**Type:** textarea

**Default:** Re-lubrication interval exceeded after the PM task was merged into a longer cycle during a schedule rationalisation.

#### Corrective and preventive actions

**Key:** action

**Type:** textarea

**Default:** Restore monthly lubrication task, add ultrasound check to route, review other merged PM tasks on the same line.

**Blocks:**

#### Failed Component Teardown Report

**Body:** Site: {{company}}
Asset and component: {{asset}}
Work order: {{wo}}
Date: {{date}}
Inspected by: {{inspector}}
Operating hours: {{hours}}

#### Prior Warning

**Body:** {{warning}}

#### Condition as Found

**Body:** {{condition}}

#### Failure Mode

**Body:** {{mode}}

#### Probable Root Cause

**Body:** {{cause}}

#### Corrective and Preventive Actions

**Body:** {{action}}

#### Evidence Checklist

**Table:**

**Columns:**

- Item
- Collected (Y/N)
- Reference or location

**Rows:**

**0:** Photos before cleaning

**0:** Photos after cleaning

**0:** Lubricant sample

**0:** Part number and batch

**0:** Condition monitoring data

#### Approvals

**Signatures:**

- Inspector
- Reliability engineer
- Maintenance manager

**Notes:** Photograph parts before cleaning and keep the failed component until the investigation closes. Probable cause is a judgment, confirm it with operating history and, where the cost justifies it, a laboratory failure analysis. For serious or repeat failures use a full root cause method as well.

## Content

**Intro:** Every failed part is a free lesson if someone writes it down. This teardown report records what the component looked like, how it failed, whether the condition monitoring warning was right and what you changed, so the same failure does not return.

**Sections:**

#### How to use the template

**Body:** Complete the report when the component is removed, not weeks later. Start with the work order, asset and operating hours, then record the warning that existed before failure, the condition as found and the failure mode. Write a probable root cause and the actions that follow. Tick the evidence checklist, export to PDF and attach to the work order in your CMMS or ERP.

#### Failure modes to choose from

**Body:** The list covers the common categories in rotating equipment. Fatigue spalling follows normal end of life or overload. Lubrication starvation shows heat discolouration and smeared surfaces. Contamination produces dents and abrasive wear. Misalignment or overload gives off-centre wear paths. Electrical fluting shows regular marks from currents passing through bearings, typical on drives. Installation damage often appears early in life. Choose the one that best fits and note any secondary modes in the condition field.

#### Closing the loop with condition monitoring

**Body:** The warning field is what makes this template useful for a predictive program. Did the technique detect the fault, how early, and was the response timely? If the failure had no warning, record that too. Over a year these entries show which techniques and intervals work for your assets and which P-F intervals need rethinking.

**Bullets:**

- Was the warning raised before removal and by how many days
- Was the lead time enough to plan parts and labour
- Did the diagnosis match the teardown finding

#### Common mistakes

**Body:** Teams often clean the parts before photographing them, discard the failed component the same day, name the cause as simply bearing failure, or write actions with no owner. A cause that names the mechanism and the missing barrier, such as a lapsed lubrication task, leads to better fixes.

**Cta:** Netray can help store teardown findings against equipment and failure codes in your ERP so repeat failures become visible.

**Faq:**

#### Is this a root cause analysis?

**Answer:** It is a teardown record that supports root cause analysis. It captures evidence and a probable cause. For major failures, follow it with a structured method such as 5 Whys, fault tree or a formal investigation.

#### Should I send parts to a lab?

**Answer:** Send them when the cost of the failure, safety risk or repeat nature justifies it. Keep the part, photograph it, and avoid cleaning surfaces that a lab will need to examine.

#### Can I use it for seals and gears?

**Answer:** Yes. Change the failure mode list to suit by editing the exported document. The structure of prior warning, condition, mode, cause and actions applies to any component.

#### Where should I store the reports?

**Answer:** Attach each report to the closed work order or failure notification so it follows the asset. Keep a shared folder index by asset and component type.

## Search terms

failed bearing inspection report, component failure analysis report template, teardown inspection report, post failure inspection form, equipment failure report template, failure mode documentation template, bearing failure analysis form

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