Downtime Collection Mode

Automatic

In automatic mode, a direct connection to the PLC enables real-time recording:

  • Exact machine stop and start times are recorded.
  • The start and stop times cannot be modified manually.
  • Machine stops as short as one second are recorded by the PLC.
  • Downtime reasons can be automatically identified or later assigned by an operator.
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In automatic mode, downtime is recorded for all machines in the line with PLC signals available.

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Manual Real-Time

In manual real-time mode, operators manually control machines stop and start events, resulting in the following characteristics:

  • Recorded times are intended to align with actual machine start and stop events.
  • Additional effort is required from operators.
  • Accuracy is lower compared to automatic data collection.
  • Stop and start times are often based on operators estimation.
  • Short duration stops are not usually recorded by the operator.
  • Recorded reasons represent the operator’s understanding of the issue.
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Manual Retrospective

Operators either log the duration of the downtime:

  • At the end of the Machine Stop.
  • Or summarized at the end of the Job or Shift.

The start and stop time of each machine stop is not logged.

  • Only total downtime duration is logged.
  • The total duration is an estimate, usually based on paper notes from the shift.
  • Short stops are usually excluded.
  • Recorded reasons reflect operators understanding of the issue.
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