Downtime Analysis – Solutions for businesses (Part 1)

If you are looking for a solution to the productivity issue that is affected by downtime, this article can give you an answer.

How to analyze downtime?

Analysis of downtime is not easy, especially when you cannot identify what is important information. Therefore, it is very important to collect the correct stop parameters. Therefore, the first thing you need to do is record the entire time the machine stops working in the following form:

– Stop position (classified by Area / Line / Machine Type)

– Check if the machine stop is in the production plan or not

– The time it takes for the device to return to normal operation (The time the machine stops working)

– Who operates the machine?

– If the machine stops due to repeated errors, note the error list

In addition, the manager also needs some other information to support the analysis (necessary but not required):

– Maintenance activities performed by whom? How long does the machine stop to start maintenance?

– Economic impact due to machine shutdown (How much money the company has lost during the downtime: Calculate the average profit generated if the machine is still operating normally during the actual downtime).

After sorting out the unplanned shutdowns and the planned shutdowns, managers need to calculate the downtime for each fault category to simplify data collection. Many organizations have chosen to go beyond just analyzing unplanned downtime to focus on troubleshooting. However, this is not necessarily effective. The machine stopped to set up, adjust (in the plan) the device operating at low speed is the factor affecting productivity. In fact, losses in equipment setup and adjustment are often felt less clearly during production. Some activities that cause this loss include: the process of setting up and starting at the beginning of the shift, while changing orders, changing molds, changing technology parameters, missing / changing materials, etc.

Besides, the device is operated at a lower speed than the design / standard is also an issue managers should be concerned about. This factor is not included in downtime, but is also a significant reduction in productivity if present for a long time. Some of the situations that may be encountered in this loss may be operating the equipment in inappropriate conditions (environment, materials, etc), operating the device at speeds lower than the design speed or the operating standard. dirty, worn / worn onions, equipment / components, incompetent operators, etc.

(to be continue)

Productivity and Quality Office