Apply “Digital Six Sigma”
To Increase Equipment Efficiency, Save Costs and Drive Customer Satisfaction
Machines experiencing downtime are dead capital – consuming attention and workspace without creating products that create revenue. Worse still, a broken machine may lead to missed client deadlines, ruining relationships and putting at risk future orders. On the other hand, planned downtime is required to ensure that machines receive the care and attention needed to continue production at the optimum speed and quality levels.
In a quest for finding that elusive optimal balance between cost, machine downtime, and production output (quality and speed), manufacturers have turned to process control techniques such as “Digital Six Sigma” to capture insights into production processes and determine maintenance needs.
ei3 Downtime Tracking app enables "Digital Six Sigma"
Capture machine running time accurately, track downtime, record downtime reason codes, and perform the analysis needed to optimize production in a practical, cost-efficient manner.
The popular Downtime Tracking app from ei3 makes it easy for companies to capture and analyze machine downtimes automatically from the machine control PLC. ei3’s powerful analytics and visualization tools provide a Pareto analysis of downtime for one machine – or the entire floor. It also computes MTBF and MTTR of equipment. The ei3 analytics follow established best practices and give manufacturing managers the insights they need for their operations. Most importantly, Downtime Tracking helps managers decide how, when, and where to focus their resources on time and money to get the best ROI of continuous improvement programs aimed at increasing asset utilization and reducing downtime events.
With ei3’s Downtime Tracking, manufacturers can analyze the influence of various factors, such as shifts, jobs, tools, and recipes, to pinpoint if it is a machine malfunction or difficulty making a specific product or just an operator who could benefit from some additional training. After improvements are made, the app shows how the investment has paid off.
1. See Downtime as it happens
ei3’s easy to use interface allows operators to quickly visualize machine downtime and verify the downtime reasons assigned by the system. The operators are free to add additional information about downtime events, add or correct reasons codes where that is necessary. The data is immediately aggregated and compiled into real-time PARETO charts.
2. Automatic Analysis
Separate the “Important Few” from the “Trivial Many”. Get to the root cause of the most damaging downtime events – and correct these! The Pareto chart created is based on automatic downtime tracking and operator feedback. Operators can quickly assess the most impactful downtime reasons and focus their attention on fixing these.
For example, if changeovers are impacting your delivery capabilities, you may take specific actions to reduce changeover times. You can also dive deeper into the data to find additional information that may aid in identifying a suitable fix; for example, changeovers may be particularly painful on specific days or shifts. Operator notes added to these events may add additional insights.
3. Generate Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR) Reports
Understand how long and how often a particular error code (or set of codes) occurs on a machine and how long it takes to repair it.
4. User-configurable automatic alerting via SMS, e-email, pager
Use custom alerting to notify yourself or your teams of events that need attention. For example, a particular maintenance alert may create an automatic SMS notification to the maintenance crew. This reduces the time it takes for the operator to contact supervisor who then reaches out to the maintenance team.