Situation in production
The machine is down
A machine stops. How often, for how long and why, and do you find out in time?
What happens
A machine stops, briefly or for a long time, planned or unplanned.
What should apply
The machine should produce to plan and cycle time during the planned time.
Why it is difficult
- Short stops are rarely recorded and disappear from the statistics.
- Different shifts give the reason differently, or not at all.
- Stop time often shows only afterwards, when it is too late to reprioritise.
The context that is needed
- When and for how long the machine was down
- The reason, from a shared list
- Order and part
- Whether the stop was linked to a quality problem
- Shift
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.
Same situation, different questions
Who needs to know what
The same event looks different depending on which decision you have to make.
The same evidence for everyone
- When and for how long the machine was down
- The reason, from a shared list
- Order and part
- Whether the stop was linked to a quality problem
- Shift
Asks
"Why did the machine stop, and what should I enter?"
Decides
Reason, and whether help is needed.
Asks
"Where do we lose the most time, and what should be fixed first?"
Decides
Which losses are prioritised.
Asks
"Is the same reason recurring?"
Decides
Whether an improvement or a maintenance job should be done.
Asks
"Do the stops affect deliveries and capacity?"
Decides
Whether resources or planning need to change.
What may follow
- 01Enter the reason at the machine
- 02Fix and restart
- 03Prioritise the largest losses
- 04Follow up stop time over time
Knowledge
Concepts that help
Where Rektron can help
What is available today
Eyesight can track machine status, stop time and stop reasons. Machine signals can be collected from PLCs and sensors.
Similar situations
Do you recognise the situation?
Tell us what it looks like where you are, and we will go through what is needed to handle it.