Solution
Production follow-up: stops, reasons and time
Machine status, stops and stop reasons while the shift is running, in the same platform as the quality data.
The problem
Production knows the machines stop sometimes, but not exactly how often, for how long or why. Without those figures it is hard to prioritise improvements.
Relevant for: Operator, Production, Management
The context in production
Availability, performance and quality rate decide how much a machine or line actually produces. Together they form the key figure OEE, overall equipment effectiveness.
To improve, you need to know where the losses occur: stops, changeovers, slow cycles or scrap. And you need to see it while the shift is running, not in a report the week after.
Why it matters
Unplanned stops and long changeovers eat capacity. Without data, improvements are prioritised by whoever is loudest instead of by what costs the most.
When quality and production have different figures, it is hard to see that a quality problem and a capacity problem often have the same cause.
In principle
A stop with time, reason and decision
The machine signal gives the time. The reason is entered at the machine. Summed over weeks, it shows where the time goes and what to deal with first.
What does it take for a stop to be improved, and not just forgotten?
Illustration · Example dataMachine status during one shift
01 · Machine
Stop
The machine stops at 08:05. The time is recorded from the machine signal.
02 · Operator
Reason
The reason is entered at the machine, from a shared list: material change.
03 · Operator
Decision
Can we handle it ourselves, or do we need a setter or maintenance?
04 · Operator
Action
The material is changed. The setter is not needed.
05 · Machine
Restart
The machine runs again at 08:17. The stop is closed with a reason.
06 · Production, engineering
Follow-up
Stop time per reason over weeks shows what to fix first.
Follow-up: stop time per reason, four weeks
- Unknown reason55 min
- Material change42 min
- Waiting for setter31 min
- Tool change18 min
A stop becomes useful only when it has a time, a reason and a decision. The largest item in the follow-up is often stops without a reason.
From today to better
Common challenges, and what a better way of working looks like
What it often looks like
- Stops are recorded by hand, afterwards or not at all.
- The stop reasons are too coarse or are used differently by different shifts.
- Key figures such as OEE are calculated in Excel and are out of date when they are presented.
- Production data and quality data sit in different systems.
A better way of working
- Machine signals are collected automatically, so that stops and cycles are recorded when they happen.
- The operator enters the stop reason at the machine, from a shared code list.
- Status, stops and losses show while the shift is running, for production and for management.
- Production and quality data are in the same platform.
Rektron's approach
How we help
Eyesight follows machines and lines: status, stop time, stop reasons, cycle times and counts. Because the same platform also handles quality data, production and quality can be seen together.
Capabilities used
Production follow-up
EyesightMachine status, stop time, stop reasons, cycle times and counts per machine, part and order.
Read more →Signals from machines, PLCs and sensors
DAQData from production machines, PLCs, loggers and sensors is collected automatically.
Read more →Digital checklists
EyesightSimple checklists for routines such as shift start, changeover and maintenance, also time-scheduled.
Read more →Analysis
EyesightTrends, histograms, Cp/Cpk over time, correlation between characteristics and analysis of stops and cycles per machine, part and order.
Read more →
The flow
How it works
- 01
Signal
The machine sends status and cycles via PLC or sensor.
- 02
Reason
The operator enters the stop reason at the machine.
- 03
Overview
Status, stops and cycles are shown per machine and line.
- 04
Improvement
The biggest losses are prioritised and followed up.
What changes
- A shared, current picture of how production is going.
- Improvement work prioritised by real losses.
- Production and quality in the same data.
Read more
- Customers and references →
Companies that work with Rektron systems.
- The knowledge base →
The methods behind the solution, explained.
Technical information
- Signals from PLCs, sensors and machines.
- Integration with planning and ERP systems for order and part information.
- Status, stops and cycles per machine, part and order.
Situations
Where this becomes relevant
The situations are described without the product: what happens, what should apply and who needs to know what.
Questions
Frequently asked questions
Do our machines need to be new to be connected?
No. Even older machines can often provide a signal for status and cycle, for example via a sensor. We go through the machine park together.
Related
Solutions that fit together
Next step
Want to see how production follow-up can work for you?
Tell us about your process and your measurements. We will suggest a first step that suits your business.