December 16, 2024

What Is Downtime Tracking? Methods, Benefits, and Software Solutions

This week, we'll explore the question of what is downtime tracking. As part of achieving management success, you'll want downtime reports. Read on for the financial repercussions of idle machinery. Other areas of interest include:

• What is downtime tracking?
• Benefits of this information.
• How this differs from production downtime.
• Methods of collecting the data.

What is Downtime Tracking?

Consider this a pivotal tool to maximize production efficiency. However, the journey to operational excellence doesn't end with merely collecting data on machine stoppage. It involves a multi-faceted approach.

1. Pinpointing the causes of downtime. You have to understand what happened. What was the failure? Then you need to know why it failed. Human error? Design problem? Worn-out parts?
2. Analyzing the collected data. You may not have much information from many sources. The next step, though, is to collect everything for study.
3. Deploying strategic measures to prevent or minimize future interruptions.

Benefits of Downtime Tracking and Its Purpose

Of course, you're striving for reduced incidents of downtime. You also want efficient maintenance during those periods. By accomplishing these, you amplify production and revenue. Also, you reduce labor costs.

Beyond the immediate financial impacts, you have subtler consequences. These also can erode the foundation of a business.

What happens with downtime, especially unplanned equipment failures?

• Missed production deadlines. Customers expect timely shipments. If downtime delays those, you risk future issues. Dissatisfied customers. Reduced orders. Lost customers.
• Fluctuating product quality. If equipment constantly breaks down, then you risk a lower-quality product. Once again, you have dissatisfied customers due to intermittent production which can undermine customer trust.

Using Downtime Tracking to Improve Overall Equipment Efficiency (OEE)

Make increasing the percentage of this a goal. Identify the problem. Collect and analyze the data. Implement the solution.

Of course, the resolution will vary from equipment to equipment and each problem.

Solutions might include:

• Additional operator training. Many problems stem from human error. Proper training goes a long way to eliminating operator mistakes.
• Adjustments to maintenance strategies. This may involve better preventive maintenance. To return to the first point, technicians may require more training.
• You might need better organization in your parts department. Inventory management helps you keep the right amount of spare parts available.
• Process modifications. This refers to either production or maintenance. An adjustment of machine operation or different methodology for effecting repairs.
• Enhancements to tools and equipment. Perhaps the machine needs an upgrade or maintenance would benefit from better inventory and tools.
• Improved staff scheduling. Once again, this could range from a variety of employees. For instance, if a machine fails during a particular time of day, then you'll need to have technicians available.

Understanding Equipment Downtime vs Production Downtime

So far, we've focused on the unexpected. While you can't eliminate unplanned downtime, you can take measure to reduce the incidents.

However, companies sometimes implement planned downtime, a shutdown for example, with scheduled regular maintenance. While this means a temporary halt in production, you have an opportunity to schedule numerous activities not possible during normal operations. Cleaning, lubrication, replacement parts. You'll see more efficiency than if workers interrupted production.

For further information on shutdowns, read an article from AMACS.

Collecting Data for Effective Downtime Tracking

Schedule a reasonable time to collect data, otherwise, you won't have sufficient information. You could look at a full day's operation or a week. Once you collect the data, keep tracking for future analyses.

To extract actionable insights, collection methods should:

1. Identify any minute stoppage that collectively amounts to substantial lost production throughout a shift.
2. Implement a forced ranking system, where operators categorize each downtime period before restarting equipment. This enhances the precision of collected data. It also benefits when you sort the information.
3. Specify the machine(s) affected. With this data, you'll note patterns.
4. Specify the personnel on shift responsible for running or maintaining the machine. This helps pinpoint possible causes.
5. Note the identity of the reporting party. Remember, any relevant information could benefit you in the analysis stage.

Downtime Tracking Methods: Manual vs. Automated

In the past, you relied on operators or maintainers to meticulously record downtime in equipment logs. Unfortunately, this came with the challenge of not having accurate or complete information.

While errors still can occur, automation offers better data collection. You have numerous choices depending on what industry you're in and the company's needs.

1. Organization-wide integrated management systems (IMS).
2. Manufacturing execution systems (MES).
3. Computerized maintenance management systems (CMMS).
4. Specialized downtime tracking software connected to a machine's programmable logic controller (PLC).
5. Machine data loggers, capable of weekly data dumps, also provide an avenue for automated data collection.

Sometimes, you can use a combination of these systems to gather data. This brings in scalability benefits, especially in a CMMS.

Challenges in Implementing Downtime Tracking Methods

While downtime tracking methods will have their benefits, you also have to consider a couple of challenges.

• Transition from manual to automated methods. Issues include coworker resistance and lack of training. Before you make any changes, plan accordingly. Watch for training opportunities.
• Additionally, ensuring the integrity and security of collected data. One solution is to research whatever system that interests you. For example, question the security measures of a CMMS provider. Ask about hosting and self-hosting.

Opportunities with Downtime Tracking Software

The opportunities afforded by robust downtime tracking systems far outweigh the challenges.

• Real-time data insights. Depending on the system, you'll have the software tied into equipment. Make decisions faster for better efficiency.
• Track readings for failure, cause, and action. This provides historical data used for evaluating machine reliability and maintenance effectiveness.

Future Trends in Downtime Tracking Software and Technology

Technology continues to advance. Watch for changes in systems for tracking.

• Artificial intelligence (AI), although a new field, will play more roles in the future.
• Machine learning (ML) algorithms hold promise in predicting potential downtime events based on historical data patterns.
• The Internet of Things (IoT) provides better opportunities. machine connectivity. Smart sensors and devices embedded in machinery enable real-time monitoring and data collection. These contribute to a more comprehensive understanding of operational dynamics.

Downtime Tracking Methods and Software: Key Takeaways

What is downtime tracking? This is a record of the availability of your assets, equipment, vehicles, etc. Why do you need it? Many industries and companies rely on tracking downtime because the information helps the bottom line. This could mean production quantities and delivery schedules. This also affects maintenance operations.

Tracking readings and information such as depreciation helps extend asset life. You're not spending money before you need to replace machinery.

Of course, preventive maintenance (PM) goes a long way to reducing costs and upping the reliability of assets. Normal equipment operations and downtime information help shape PM strategy.

Ensuring Data Accuracy and Security with CMMS

A CMMS benefits maintenance departments in more than just asset management. Inventory, PM, Work Orders. Purchasing. It even extends to human resources and barcoding.

You'll find a quality CMMS a great tool for recording readings and collecting downtime data. Review the challenges discussed. Before investing in a system, ask the provider about training opportunities. This will aid in a smoother transition.

Ask, too, about scalability and customization. You don't want modules you won't use. Look for a company that will help you with features that you'll need. Also, discuss customization for special reports and features that your individual company can use.

Mapcon Technologies has continued to develop a world-class CMMS over the last forty years. U.S.-based programming and support.

Call today for a free demonstration. 800-922-4336 Ask about the downtime tracking features.