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Probably the most important contributor to inefficiency in a manufacturing surroundings is gear downtime. To handle this situation, manufacturing corporations use downtime monitoring software program to categorize varieties of gear downtime and develop procedures and methods to scale back or remove the issue. In right this moment’s high-speed and hyper-competitive market, producers want each benefit they will to keep up market share. And software program is a crucial part of these methods.
What’s Downtime Monitoring?
Operators are sometimes tasked with recording downtime occasions on the machine or spindle stage to observe gear downtime. These occasions are damaged down into classes akin to spindle or zone-specific downtime, machine-related downtime, materials shortages, high quality issues, common upkeep, and others.
Downtime monitoring can embrace primary info akin to begin and cease time and the rationale for the downtime. It might even have extra detailed info such because the spindle quantity, ambient situations akin to temperature or humidity, or different observable phenomena or anomalies.
Manually accumulating downtimes just isn’t solely extremely time-consuming on the a part of each operators and managers, but additionally susceptible to errors. It’s extremely inefficient and never actionable, paving the best way for automated information assortment options that may inform you of downtime occasions in real-time and assist you perceive long-term tendencies by way of analytics.
Why is Downtime Monitoring Essential?
Monitoring downtime is important as a result of understanding the state of the gear or its subcomponents can assist managers make choices to enhance effectivity. As soon as analyzed, it may be used to develop improved Customary Working Procedures (SOPs). With higher SOPs, operator duties, ergonomics, materials staging, and different facets of apparatus operation will be optimized.
Research present that as much as 70% of corporations are unaware of the time and date that their gear is due for upkeep. Upkeep administration can use downtime monitoring to develop preventive upkeep methods to restrict downtime and enhance total gear effectiveness.
Funding in capital gear can take a big share of accessible capital. By decreasing downtime, corporations can cut back Capex and plenty of of its related prices. This will additionally unlock capability within the type of present gear that helps delay or cut back total capital expenditure and frees up cash for working money and different enhancements.
Gathering Downtime Information
Conventional information assortment of downtime occasions was solely guide. Paper types on clipboards, “bother tickets,” spreadsheet-based evaluation, and formulation have been used to gather downtime information. As soon as this information was collected, it wanted to be aggregated, entered right into a spreadsheet, and delivered in a consumable report back to managers and others who may make choices.
As OEM corporations started so as to add or embed digital info assortment to their gear, causes may very well be streamlined. However with out complete software program and automatic evaluation, the data nonetheless required assortment and collation. Guide and partially automated recording of downtime occasions each lacked the good thing about real-time evaluation.
Actual-time downtime monitoring options akin to MachineMetrics, autonomously accumulate machine and operator information to not solely allow operators and managers to get notified of downtime instantly but additionally be capable of analyze information for lengthy phrases tendencies.
Enhance Effectivity by Utilizing Downtime Monitoring Software program
Through the use of downtime monitoring software program, producers can enhance the effectivity of producing. Insights are real-time, evaluation is unbiased, and information assortment of downtime occasions is automated. This streamlines the gathering course of and improves effectivity all through the manufacturing unit.
High Advantages of Utilizing Downtime Monitoring Software program
Producers can detect tendencies and analyze information primarily based on real-time insights and contextualized reporting by utilizing real-time monitoring software program. Advantages embrace:
Reduces Human Error
Downtime causes complications for any trade. However in manufacturing, a better share of that downtime is brought on by human error. A examine in 2017 confirmed that unplanned downtime in manufacturing was as excessive as 23%. The software program helps determine incidents brought on by human error versus different causal classes. Figuring out the frequency of those errors and the place they occur can assist managers enhance labor utilization and skillsets by designing improved coaching. It may additionally assist engineers set up or enhance sensors, guards, and different mitigation strategies to scale back human error.
Eliminates Bias
Guide information assortment is usually riddled with bias. Completely different operators and technicians could report or categorize occasions otherwise. This results in ambiguous or defective decision-making as a result of the answer doesn’t totally handle the basis reason for the issue. Bias might also be evident within the analytical part of knowledge assortment. Managers could interpret information otherwise or assign totally different rank priorities to some points greater than others. And the dearth of real-time availability of knowledge could compound the issue.
Improves OEE
With downtime monitoring software program, upkeep administration can have extra confidence in designing preventive upkeep applications. They know the precise reason for unplanned downtime with real-time information and insights and may incorporate this into their resolution. It may additionally assist optimize deliberate upkeep efforts by permitting for prescriptive or predictive upkeep primarily based on the information. As unplanned downtime improves, upkeep administration can optimize their applications, and total gear effectiveness will increase, bettering effectivity and decreasing upkeep prices by way of each labor and components.
MachineMetrics permits producers to trace OEE in real-time by autonomously accumulating and standardizing machine information.
Will increase Capability
Monitoring downtime with software program can enhance the manufacturing course of by unlocking capability. In right this moment’s high-speed manufacturing world, OEM equipment will be pricey. That is essential for all producers however is particularly burdensome for small and medium-sized companies. Through the use of downtime monitoring software program, downtime is diminished throughout many alternative classes. As talked about above, these could embrace upkeep, bias, and human error. However it could actually additionally assist enhance processes and even enhance facility format. Cumulatively, these adjustments improve capability all through the manufacturing unit. By bettering capability, corporations can cut back their capital expenditure program and release working capital.
Facilitates Course of Enchancment
Course of enchancment is without doubt one of the most important advantages of monitoring downtime with software program. Automated information assortment mixed with analytics permits decision-makers the chance to conduct root trigger evaluation and optimize, change, or alter manufacturing processes. And with real-time information, entire classes of downtime will be eradicated or considerably diminished. In others, ground format, machine place, materials stream, WIP, and different manufacturing stream processes may also be improved to reduce downtime. Upkeep administration also can enhance processes and total gear effectiveness by predicting failures or staging restore components close to the gear earlier than use. Along with enhancing OEE, these new processes can cut back operator error, remove bias, sharpen coaching, and enhance total skillset and labor utilization throughout the enterprise.
Reduces High quality Fallout
High quality loss on the machine stage is one other class of downtime for which there are numerous contributing components. It might be gear situations the place put on and tear are rising fallout. Or it could be that materials or feedstock errors trigger high quality fallout or harm to the gear once they fail. Understanding the frequency and the diploma to which they contribute to downtime can provide a broad vary of options for producers to interact in high quality assurance, akin to improved high quality of uncooked supplies from distributors, higher upkeep response or preventive upkeep applications, or course of enchancment for inspection.
Improves Choice Making
Manufacturing administration could make higher choices as a result of information is real-time and tied to analytics. With out the bias inherent within the guide or semi-automated assortment of downtime information, software program evaluation is sharper and extra more likely to be actionable inside a crucial spectrum to permit for enchancment. By figuring out exactly what the classes of downtime are and their rank of precedence, managers can commit time to people who will ship the very best ends in essentially the most cost-effective method.
What Options Ought to Downtime Monitoring Software program Have?
Downtime monitoring software program can change the best way a producing operation works. By having correct information on the classes, time, precedence, and motive for every downtime occasion, producers can handle capability, effectivity, OEE, and value in real-time and work to enhance them. MachineMetrics affords best-in-class software program with a sophisticated analytics platform and operator instruments to assist visualize downtime and ship actionable insights to the manufacturing ground.
Let’s check out a number of the options MachineMetrics has that can assist you observe and cut back downtime throughout your store ground:
Automated Machine Information Assortment with Operator Perception
MachineMetrics autonomously collects and standardizes machine information throughout any make and mannequin of machine. This propagates a standardized stream of downtime information regardless of the gear on the store ground, surfacing this info in each pre-built and customized studies and dashboards (which we are going to focus on beneath).
Our plug-and-play resolution connects on to the machine management and likewise collects contextual information from operators by way of tablets positioned at every machine. On this manner, producers not solely have correct downtime information instantly from the machine, but additionally information that explains the “why” behind these downtimes.
Listed here are a number of the information factors you’ll have entry to:
- Downtime class
- Whether or not the Downtime is Deliberate or Unplanned
- Period of downtime
- The machine the downtime occurred on
- The time the downtime occurred
- The shift or operator working the machine
Tablets positioned at every machine immediate operators to categorize downtime reasosn for an correct view of why machine are taking place.
Actual-Time Dashboards Reveal Downtime in Actual-Time
With dashboards positioned throughout the store ground, in addition to key info proven on every machines’ pill, each operators and managers have visibility into machine efficiency. Analyzing a real-time dashboard can inform your staff of a machine that’s falling behind anticipated manufacturing or if a machine just isn’t working so that you just or your staff can take fast motion.
Additional, this visible administration system ensures a way of accoutnability on the a part of all store ground staff, and offers them a device to higher perceive their efficiency. This visibility alone can present 20% will increase in productiveness.
Analyzing Information in Out-of-the-Field Reviews
MachineMetrics comes with pre-built studies for manufactures to take motion primarily based on correct machine information. One of the vital helpful studies in relation to udnerstnad and recufing downtime is the Downtime Pareto Chart:
This report outlines the highest causes for downtime, permitting you to prioritize your steady enchancment efforts. Moreover, you possibly can phase the information amongst totally different shifts, machines cells, and even particular person machines for a extra drilled-down have a look at the place issues could lie. This lets you perceive excessive and low performing shifts, issues with particular person machines, and jobs which have confirmed tough.
Workflows and Notifications
The great thing about automated, correct, and standardized real-time machine information is that it may be utilized in quite a lot of methods to allow higher communication, course of optimization, and automation.
Workflows permit your staff to take fast motion on downtime occasions by notifying the fitting individuals on the proper time. For instance, say a machine is down on account of a upkeep situation. A workflow will be enabled to routinely notify the upkeep staff, or create a piece order in a CMMS system.
Or, if an operator notices that materials is working low at a machine, they may manually set off a workflow that might notify the supplies supervisor, and so they can do that proper from the machine to forestall any downtime from occurring.
A textual content alert instance of a upkeep situation that may be routinely enabled by way of a workflow.
Able to Get Began?
With MachineMetrics, downtime will be consumed in easy-to-read, related studies and Pareto charts. Each operators and managers can see what fault is inflicting essentially the most downtime in real-time and act shortly to get gear up and working.
Automated downtime monitoring software program is a crucial part of producing success. MachineMetrics just isn’t solely constructed to ship worth shortly with its plug-and-play nature but additionally for use as a platform for steady worth creation. Study extra about how MachineMetrics can allow visibility and management of your store ground by reserving a demo right this moment.
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