Failed Component Teardown Inspection Report Template
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.
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Failed Component Teardown Inspection Report Template
Failed Component Teardown Report
Site: Riverside Plastics Asset and component: EXT-02 Extruder gearbox, output shaft bearing Work order: WO-558214 Date: 2026-10-16 Inspected by: L. Haddad Operating hours: 14,200 hours
Prior Warning
Vibration envelope alarm raised 6 weeks before removal, ultrasound rise of 15 dB at last route.
Condition as Found
Outer race spalling over about 25% of the load zone, grease dark and dry, cage worn at one pocket.
Failure Mode
Lubrication starvation
Probable Root Cause
Re-lubrication interval exceeded after the PM task was merged into a longer cycle during a schedule rationalisation.
Corrective and Preventive Actions
Restore monthly lubrication task, add ultrasound check to route, review other merged PM tasks on the same line.
Evidence Checklist
| Item | Collected (Y/N) | Reference or location |
|---|---|---|
| Photos before cleaning | ||
| Photos after cleaning | ||
| Lubricant sample | ||
| Part number and batch | ||
| Condition monitoring data |
Approvals
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.
Capture failure history in your ERP
Optional review of how teardown findings could attach to equipment and failure codes.
Optional. The tool and every export work without this. No spam.
How to use the template
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
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
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.
- 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
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.
Frequently Asked Questions
Is this a root cause analysis?
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?
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?
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?
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.
Netray can help store teardown findings against equipment and failure codes in your ERP so repeat failures become visible.
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