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Use our Free Availability Downtime Calculator to uncover exactly how downtime is affecting your machine availability.
Get instant insights to reduce stoppages, improve uptime, and strengthen overall equipment reliability.
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How Availability Downtime is calculated
| Parameter | Meaning | Example / Notes |
|---|---|---|
| Total scheduled time (A2) | Sum of all shift times for the period being calculated. | If the machine works 3 shifts of 8 hours each, enter 24 hours. If 2 shifts, first 12h and second 8h, enter 20 hours. |
| Total scheduled non-working time (A3) | Sum of all planned non-working periods like breaks, machine warm-up, or preventive maintenance. | Lunch break, tea break, warm-up time, daily preventive maintenance. |
| Available time (A1) | Time during which the machine is available for production, after removing scheduled non-working time. | Calculated as A1 = A2 - A3 |
| Machine downtime (B) | Time lost due to unexpected issues that prevent production, despite the machine being scheduled to run. | Setup/changeover, machine breakdown, power shutdown, no raw material, inspection, etc. |
| Availability % (R) | Percentage of time the machine is actually available to produce after accounting for downtime. | Calculated as R% = (100 x (A1 - B)) / A1 |
Availability Downtime losses and their meaning
| Type of Downtime | Meaning | Example / Notes |
|---|---|---|
| Not Scheduled for Production | Time when the machine is intentionally not planned to run, not counted as downtime. | Non-working shifts, holidays, planned shutdown days. |
| Planned Non-Working Time | Scheduled pauses during production where the machine is intentionally stopped but availability is not negatively affected. | Lunch breaks, tea breaks, warm-up periods, daily preventive maintenance. |
| Breakdown Downtime | Unplanned stoppages due to failures or issues that prevent machine operation and reduce availability. | Machine breakdown, power failure, electrical/hydraulic failure, accidents, crane breakdown. |
| Minor Stoppages / Idle Time | Short interruptions where machine is not producing although scheduled to run, reducing availability subtly. | Operator absent, material delays, part load/unload, small jams, waiting for inspection. |
| Setup & Adjustment Downtime | Time lost during tool changes, job changeovers, and adjustments affecting the machine’s availability. | Tool or fixture changes, program loading, offset setting, job changeover. |
| Quality-related Downtime | Time spent fixing quality issues or reworking parts when the machine does not produce good output. | Rework, scrap handling, adjustments after inspection. |
| Raw Material / Supply Downtime | Machine is ready but cannot run due to lack of raw materials or consumables, reducing availability. | No raw materials, coolant shortages, missing tools, waiting for consumables. |
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