Downtime analysis – Solutions for businesses (Part 2)

After identifying planned downtime issues, managers can focus more on unplanned downtime analysis. This problem usually consists of two main types: Local failure resulting in the machine must be stopped for maintenance or minor disruption to the operation process.

Local failure is the most visible loss in production because of its irregularity and its obvious impact on continuous production in the factory. Cases of this loss include mold / die failures, unplanned maintenance operations, general mechanical / electrical failures or parts of equipment or non-operating equipment cases. as required (function / technology parameters). Pause stops, to distinguish them from local malfunctions, often include incidents that cause short downtime – for example, less than 5 minutes – and often do not require the presence of a technician. Technical / maintenance. Actual situations may include problems with on-line flow, jamming / clogging, problems with feeding / guiding parts, wrong supplies / materials, obscured sensors, incidents small in the following stages, etc.

To clean up the above data and prepare for analysis, an extremely useful tool at this time is the Pareto chart. Vilfredo Pareto has established the 80/20 rule, which means that 80% of the problem is affected by 20% of the main causes. In this case, managers can find that 20% of the problem is the cause of 80% of downtime during production.

Looking at the chart, we can see the left vertical axis is used to measure the frequency of occurrence, but it can also be replaced to measure costs or a different unit of calculation depending on the purpose. The vertical alignment on the right is used to measure the cumulative percentage of the total number of occurrences, total cost, or the sum of a specific unit of measurement depending on the purpose. Because values ​​are arranged in descending order, the cumulative function will be a concave function.

Using the above Pareto Chart example, managers can easily recognize that the way to reduce 78% of the late work time for employees is to solve the first three problems (transportation, care). children, public transportation), it is more effective than trying to solve all problems at once.

After using the Pareto chart to identify problems that need to be addressed in advance, managers can begin to analyze in depth the causes of downtime. At this stage, the remaining unused data will become a valuable resource: The amount of time that the machine waits from the time the machine started to malfunction until the machine is repaired indicates whether the service work well or not; The number of repetitive incidents on the same machine or by the same operator indicates that the problem is on the machine or the person, etc. By identifying and solving problems at the root, your organization can significantly improve productivity by reducing downtime.

Productivity and Quality Office