Downtime’ is one of the most dreaded words in manufacturing. While production downtime is part of life in a factory, managers, operators, and technicians constantly strive to reduce it and mitigate its effects.
MachineMetrics can automatically notify team members of a downtime event. This can be used to deliver a notification at a tablet placed at the machine, a text message to a cell phone, an email, or even be used to automatically create work orders in a CMMS.
Unplanned manufacturing downtime can be calculated based on lost time or lost revenue dollars. By tracking time, managers can review the reasons for downtime and develop strategies for process improvement to prevent the event from occurring as frequently or at all. By tracking dollars, companies see the impact on the cost of the product and its impact on revenue.
The formula for calculating unplanned downtime using a time measure is:
Unplanned Downtime = (Time Asset is Down / Total Time) x 100
This measurement can be applied to individual spindles, machines, shifts, departments, or factories depending on the level of focus needed by the person reviewing the data.
Calculating unplanned downtime as a cost may vary significantly from a few hundred dollars to tens of thousands of dollars per hour, depending on the operation’s size, complexity, and the number of workers impacted. The formula for calculating unplanned downtime for lost dollars is:
Cost of Unplanned Downtime = Average Hourly Wage x (Time Asset is Down/Total Time) X Number of Employees Affected
Other things can easily add to the total cost of unplanned downtime if the cost of overhead and other variables are included.
Standard work is a proven method for systemizing processes, operator motion, and other variables within production. Using standard work to ensure everyone is working the same way reduces unplanned manufacturing downtime significantly.
MachineMetrics can automatically update important metrics that play a part in standard work and standard operating procedures. For example, we can send updated part counts and cycle times to an MES, ERP, or wherever else jobs are managed.
Real-time production dashboards above the shop floor provide immediate visibility into the status of machines.
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