Downtime Tracking & Analysis Software- Shopfloor-Online Production

Drive improvement with machine, equipment and production downtime analysis and tracking

Powerful downtime analysis reports to accurately track machine and equipment downtime and reduce losses.

How can machine downtime affect manufacturing organisations?

Downtime is a major concern for most manufacturers; a lost capacity that can never be regained. All too often, machine downtime is manually recorded on paper and with poor accuracy, which makes it hard to analyse or drive improvements.

How can a machine & equipment downtime tracking and analysis software benefit production?

The Downtime Analysis & Tracking module of Shopfloor-Online MES software:

Automatically captures start and stop events and downtime reason codes by direct connection to machines
Alternatively captures stoppages manually where no machine connection exists
Increases visibility of stops and reacts faster
Drives improvements based on accurate analysis of machine & equipment downtime and downtime losses

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What are the benefits of the Downtime Analysis & Tracking module?

Reduce downtime losses – downtime is usually the biggest factor in OEE, even small improvements in up-time have considerable impact on the bottom line
Visibility – through plant-wide visibility on downtime with live dashboards
React faster – to get production running again
Reduce losses – enable improvement decisions to be based on real data
Build up a detailed history of downtime events for analysis – know where the real losses are and where to focus
Gain insight – for example the hidden cost of short stops
Continuous Improvement – identify common problems and focus improvement activities

Features
Case Studies
Go Further

Accurate machine & equipment downtime data

Automatically record downtime events and fault codes in real-time direct from PLCs
Get accurate durations for stoppages
Alternatively, manually record machine downtime duration stop reasons, typically at the end of each shift or production run
Dual-mode – have some processes collect data automatically and others manually
Invest in automatic data collection for analysis that will lead to feasible gain and the benefit of a plant-wide unified recording system

Add-On data capture PLCs

Where you can’t take data from existing equipment, Lighthouse Systems’ support team can install inexpensive ancillary PLCs to capture downtime

Record downtime reasons

Create your own two tier hierarchy of downtime categories and reasons for each type of process
Additionally classify all stops as one of: breakdowns, technical (related to equipment and process), quality, operational issues, unplanned stops (e.g. material shortages, man-power-shortages) or planned stops (e.g. planned maintenance, change-overs)

Detailed downtime reporting and analysis

Analyse stops by factors like process, machine, line, department, shift, crew, downtime reason, product etc.
Reports can be run ad hoc or scheduled, or can be used to generate email/SMS alerts
Pareto charts for downtime analysis – top 10 losses
Production downtime trends
Gantt charts for downtime analysis
Analysis of short and long stops
MTBF (Mean Time Between Failure) and MTTR (Mean Time To Restore)

Continuous Improvement

Identify the top downtime losses and drill into the causes
Use as part of a monthly review process, helping you to identify issues and sustain the gains you make

See how manufacturers are using the Downtime module of Shopfloor-Online in conjunction with the OEE system.

Electronics

►Film coating manufacturer case study
Clear visibility of machine downtime increases productivity during a complex coating process, helping to improve output, delivery and quality.

For more insights, leverage your downtime analysis data with other modules of Shopfloor-Online MES software:

Production Counting, Manufacturing Waste and OEE – to generate real-time OEE reports and other KPIs
Repairs Management – use breakdowns to trigger repair requests to speed up response from maintenance
Labour Tracking – know the labour used, calculate KPIs like productivity