The key states are:. Ideally, the states would be determined by the machine control system, but it can also be done with calculations in the downtime tracking software. Downtime events can then be triggered by the machine state, and a start time and end time are recorded. It is also a good idea to divide downtime into major and minor stops. Minor stops could include events such as jams, blocked sensors, or minor adjustments.

Downtime events that are greater than 5 minutes are considered major stops and should be identified as either breakdowns or changeovers. After a downtime event is created, a reason needs to be identified and assigned because knowing why the machine went down is essential for problem solving. Some systems can automatically assign a reason based on the error code from the machine. Operators can verify automatically generated reasons or select the appropriate downtime reason from a pre-determined list of common causes.

Some companies even build the reason picking functionality directly into the machine controls and require the operator to select a reason prior to starting the equipment back up. This is a way to guarantee all downtime events get a reason assigned to them, but be careful because it could cause inaccurate data or frustration because the operator just wants to get the machine started again.

You need to have an appropriate list of reasons to be successful. The reason list should be small and standardized for each equipment type. The truth is that by tracking your downtime you can put preventive maintenance measures in place, helping you to come more proactive than reactive. Automated downtime tracking can be set up to record downtime in a way that works for you.

By taking note of what the results say, you can put these all-important preventive maintenance efforts in place, knowing in advance where the issues lie. It is vital that you are always aware of your company's efficiency. With automated downtime tracking software, your output production will be measured in real-time. The software can then even compare this information with the potential that could be realized. Not only can you see exactly where your company is less efficient in terms of its output, but you can also see any shifts or trends, allowing you to determine exactly what the cause of the problem might be.

When you can see what your efficiency is compared to what it could and should be, you can make the necessary adjustments and boost your business hugely, increasing your profits and stretching its reach by implementing continuous improvement programs.

By looking into the reports that this will give you, you can easily determine exactly what the biggest issue in your company is with regards to downtime. And to make this an even better way of working, it can be done in real-time. That means as soon as you experience any unplanned downtime, you can find out what, why, and how before machine uptime again. It could be operator error, it could be the equipment itself, or it might be something further reaching.

This system can even be used when it comes to planned downtime. When you can see the cause of any downtime your equipment might be experiencing, you can also see the impact on machine uptime and production. ShopFloorConnect has the ability to track the number of cycles on maintenance items that are used in the machine s , but that do not necessarily cycle 1-to-1 with any single machine; such as when you have a series of metal forming dies each of which can run in any one of 5 machines depending on demand for parts.

ShopFloorConnect can separately keep track of the number of cycles on each forming die, regardless of which machine runs it. ShopFloorConnect also allows you to set a maintenance preset for each tracked item. The Track Cycles report features the standard ShopFloorConnect delivery filters , as well as a filter that allows you to select whether to include only the tracked items that have exceeded their cycles preset, or those that have either exceeded or are within a specified percentage of the preset.

There is also a filter to specify how the report is sorted by item number, description, or percent of preset. The Track Cycles Report is typically automatically delivered on a set schedule to the personnel responsible for maintaining the tracked items.

Download our whitepaper to learn more or contact ShopFloorConnect to schedule a demo or for more information. Home Production, Efficiency, and Downtime Reports. ShopFloorConnect production monitoring software includes the following machine downtime tracking and OEE report templates: Downtime Summary The Downtime Summary tracks reasons for downtime by machine.

Sample Tabular Uptime Efficiency Report Production Summary Report This tabular production efficiency report shows a line for each job run in each of the selected machines. Sample OEE by Machine Form Report OEE By Machine Graph This machine monitoring and downtime tracking software also provides a report that shows a bar chart with the Overall Equipment Effectiveness OEE for the selected machines over longer time periods This production efficiency report features the standard ShopFloorConnect machine, delivery, and date range filters , as well as filters to allow you to include offline and or changeover time as either planned or unplanned machine downtime.

Sample State Summary Report State Summary Report The production monitoring software also provides a State Summary Report that generates pie charts and a table that shows the amount of time the selected machines have spent in each of the five machine states running, idle, unplanned downtime, planned downtime, and changeover over the selected time period.

To begin, setup your data columns on Worksheet1 renamed Log to collect the following information related to the each downtime event:. To make it easier to enter data into this Excel spreadsheet, create separate worksheets to store the lists that will be become drop down options on the log.

Here are the ones used in the example spreadsheet to store lists and reports. Once you have entered the items in each list on the appropriate worksheet, you can create drop down lists on the Log worksheet by following these steps:.

Highlight the cells on the Log Worksheet that you want to access a list. For example, for shifts, select B9 through B Go to the worksheet with the list and highlight all the choices in the list plus blank rows for possible additions in the future.