Articles, Blog

Reduce Downtime

November 28, 2019

Hi my name is Bryan Sapot and i’m the
founder and CEO of SensrTrx. Today we’re gonna talk about how you can use SensrTrx to diagnose and fix downtime issues so create more
availability for your machines increase your capacity and throughput because
your machines are going to run more often most companies talk about this (and) we see it in marketing all the time but very few
people actually show how they do it so… This is an example a very simple example
of a sandwich line. The sandwich line has multiple steps to the process where
breads being fed in, we’re putting various meats and cheeses on the breads, and then maybe then maybe it’s frozen towards the end and then it’s packaged
and we can see here we’re looking over a 24-hour period on this sandwich line
where we have quite a bit of red on this timeline so each one of these red bars
represents some downtime sort of the blue bars the difference between the
blue and the red is planned versus unplanned maintenance so the blue is
planned downtime so for 28 minutes this morning it was not scheduled then we
started up we ran a little bit we ran two hundred sixty two sandwiches through the line and then we had some more downtime we had to have maintenance come over and do some production support so you can see every hour we have some
green and some red it kind of looks like we have more red than more green here so let’s look at the details associated with that so we can scroll down a little
bit and notice here we’ve had a total of two hundred and fifty eight minutes of
downtime on this particular shift and we can see it by hour as well so this is
showing us down time as the red line in minutes by hour so you can see here we
had 42 minutes at the seven o’clock hour and we were able to make 2440 sandwiches so you can see that this increased downtime is having some pretty big
impacts on our production so what is this downtime actually that’s showing up
in this graph and this time line up above well we can break it down by our
in terms of is it maintenance or is it production support so meaning is
maintenance coming over and having to do something or is it production related
downtime such as change over something getting stuck a problem that
production team can fix so we can see that we don’t have a ton of maintenance
support here most of it is coming through the production team and then we
can dive down into and look at a Pareto chart of where our biggest problems are
and we can see that the butter applicator is causing almost all of our
downtime 58 minutes of that and then we move to production support and then a
tunnel issue so now if we’re trying to get to our Pareto number which is what’s
representing 80 percent of our downtime we can take a look at that and see that
it is the first five so it’s also a tunnel issue we also have some not
scheduled time that’s pretty big and a cutting head adjustment so I can take a
look at another view of those downtime details in the table so maybe I want to
look at total downtime in terms of minutes so here we see the same thing
the Pareto is showing us that butter applicator is our biggest problem next
production support and then a tunnel issue but we can also see how what’s the
average duration of this downtime so the butter applicators down for 15 almost 15
minutes at a time 14 and a half minutes and that’s happened four times
production support doesn’t last as long that’s happened four times as well same
with the tunnel issue we also noticed that not scheduled from an average
perspective is one of the highest down times that we have so we can make a
choice about what we attack first but it seems like we need to deal with this
butter applicator and then we better see what’s going on with production support
and then if you ever have to if you ever have to moderate a dispute between the
maintenance team and the production team as to who’s causing more downtime we can categorize it by by category showing you that 71 percent of the downtime is
associated with production and then 28 percent is associated with maintenance
activities so it gives you a high-level view of how you can quickly diagnose
downtime issues on a more complex production line but this works the same
whether you have multiple machines in a line or you’re dealing with just a
single machine such as a machine tool but you can find out more at our website
so take a look there

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