Contact Us
Try our Free Operator Efficiency Calculator today and see how effectively your workforce is performing on the shop floor.
Get instant insights to identify performance gaps, optimize labor utilization, and improve productivity, consistency, and overall operational efficiency.
Improve your Machine Downtime for free
How Machine Downtime is calculated
| Category | Description | Details / Formula |
|---|---|---|
| Overview | What does this calculate? | Calculates the machine downtime percentage. |
| Overview | Meaning | How much time is the machine idle when it could have been producing? |
| Overview | Instructions | Enter all values for the duration for which you are doing the calculation. |
| Availability | Description | Details / Formula |
| Availability | Total scheduled time (minutes) | A2 — Sum of all shift times. Example: 3 shifts × 8 hrs = 24. Example: 12 hr + 8 hr shifts = 20. |
| Availability | Total scheduled non-working time (minutes) | A3 — Scheduled breaks like lunch, tea, warm-up, daily PM, etc. |
| Availability | Available time | A1 = A2 − A3 |
| Downtime | Description | Details / Formula |
| Downtime | Machine downtime (minutes) | B — Sum of ALL downtimes between or inside production cycles where the machine is not producing: Setup change, breakdown, power shutdown, waiting for raw material, inspection, crane breakdown, operator away, etc. |
| Downtime | Downtime % | Downtime % = (100 × B) / A1 |
Machine Downtime losses and their meaning
| Type of downtime | Meaning | Examples |
|---|---|---|
| Not scheduled for production | Time when the machine is not planned to run. This time is not counted as downtime. | Non-working shifts, holidays, planned shutdown days. |
| Planned non-working time | Scheduled breaks or activities where the machine is intentionally stopped. | Lunch breaks, tea breaks, warm-up time, daily preventive maintenance. |
| Breakdown downtime | Time when the machine is planned to run but cannot due to a failure. These are major stoppages that require a recorded reason. | Machine breakdown, power failure, electrical issues, hydraulic failure, accident, crane breakdown. |
| Minor stoppages / idle time | Short stoppages or small delays where the machine is not producing even though it should. Too small to categorize individually. | Part unload/load delays, operator away, waiting for inspection, waiting for raw material, small jams. |
| Setup & adjustment downtime | Time lost during changeovers, adjustments, or tool changes required to restart or continue production. | Tool change, fixture change, program loading, job changeover, offset setting. |
| Quality-related downtime | Time spent correcting issues or reworking parts where the machine is not producing new good parts. | Rework time, adjustments after inspection, scrap handling. |
| Raw material / supply downtime | Machine is ready to run but cannot operate because required materials or consumables are unavailable. | No raw material, no coolant, missing tools, waiting for consumables. |
From Our Blogs
Most factories think “30 minutes of downtime is normal.”But when you add it across machines and shifts, it quietly becomes
Causes of downtime in manufacturing The causes of downtime in manufacturing can be divided into Low hanging fruit and High
Lean manufacturing, or Lean, is the systematic elimination of waste (‘Muda’) within a manufacturing system. Lean manufacturing is derived from
Production tracking software and Andon boards Stale data on Andon boards is as useless as stale bread, and is in