Machine downtime refers to the period during which a machine or equipment is not operational or available for use due to various reasons such as maintenance, repairs, breakdowns, changeovers, or any other unplanned interruptions in production. It is a critical metric in manufacturing and other industries where machinery plays a crucial role in the production process.
Downtime can be categorized into two main types:
- Planned Downtime: This is scheduled downtime that occurs when machines are intentionally taken offline for preventive maintenance, upgrades, or other planned activities. During planned downtime, production schedules are adjusted to accommodate the maintenance or upgrades without significantly impacting overall productivity.
- Unplanned Downtime: This type of downtime is unexpected and occurs due to equipment failures, breakdowns, shortages of input materials, power outages, or other unforeseen events. Unplanned downtime can have significant negative impacts on production schedules, leading to delays, loss of revenue, and increased maintenance costs.
Reducing machine downtime is a key objective for manufacturing companies as it directly affects productivity, efficiency, and overall profitability.
Strategies for minimizing downtime include implementing preventive maintenance programs, training personnel for quick troubleshooting and repairs, and maintaining adequate spare parts inventory. Additionally, analyzing downtime data to identify root causes and implementing corrective actions can help in continuously improving equipment reliability and reducing downtime in the long term.
Within Servitly you can define Insight Metrics based in the Downtime algorithm described below.
Inputs
The downtime algorithm takes as input the Standard System Status, available by default on each product registered in the DPS, and which may assume these states:
- OFFLINE: the product is offline (Connection Status != 1)
- DOWN_UNPLANNED: the product is in FAILURE and so not able to work.
- DOWN_PLANNED: the product is not able to work due to a planned reason, for instance, a cleaning session is running.
- IDLE: the product is not working (e.g. standby, warm-up, startup).
- WORKING: the product is working.
The Standard System Status requires to be configured on the Thing Definition, by mapping the machine states to standard states (e.g. WARM_UP → IDLE, HEATING → WORKING).
Help Center: Standard System Status
Outputs
This algorithm provides the following output information:
- Downtime Time
- Downtime Percentage
- Planned Downtime Time
- Planned Downtime Percentage
- Unplanned Downtime Time
- Unplanned Downtime Percentage