Unplanned Downtime Calculator
A machine stops at 10:15 AM. The operator waits for the supervisor. The supervisor checks the controller, calls maintenance. Maintenance arrives at 10:31. The fix takes 6 minutes. The machine restarts at 10:47. Total stoppage: 32 minutes. Nobody wrote it down as 32 minutes — it got logged as “about 20 minutes” at shift end, if […]
What Is an Andon Board? How It Works, Types & Why Your Shop Floor Needs One
It’s 2 PM. A machine on Line 3 has been running slow for the past 40 minutes. The operator knows. But the supervisor is at the other end of the floor. No one has flagged it formally. By the time the shift report comes in at 6 PM, 40 minutes of production output are gone. […]
How to Fix High Machine Maintenance Time?
When machines stop, production stops. But what hurts more is the hidden time lost in fixing them. Snapshot High machine maintenance time usually comes from reactive maintenance and poor visibility into machine problems. Most plants don’t track downtime clearly, so technicians keep fixing the same issues again and again. Manual reporting hides the real causes […]
What Is the Real Cost of Downtime in Manufacturing That No One Knows?
Most factories think “30 minutes of downtime is normal.”But when you add it across machines and shifts, it quietly becomes a huge loss. Here’s what that “small stoppage” actually costs. Snapshot 30 minutes of machine downtime may seem small but can quietly cost thousands per day. For example, 20 machines at ₹500/hr lose ₹15,000 in […]
What are the Causes of downtime in manufacturing ?
Causes of downtime in manufacturing The causes of downtime in manufacturing can be divided into Low hanging fruit and High hanging fruit. – Low hanging fruit is caused by work ethics issues. It can be fixed easily, in a short time, with little or no investment. – High hanging fruit is caused by systems (i.e., […]
8 Wastes of Lean Manufacturing
Lean manufacturing, or Lean, is the systematic elimination of waste (‘Muda’) within a manufacturing system. Lean manufacturing is derived from the Toyota Production System. To understand the wastes of Lean, it is necessary to first understand what Lean is. A machine manufacturing system on Industry 4.0 can play a great role in reducing the 8 wastes […]
Production tracking software and Andon boards
Production tracking software and Andon boards Stale data on Andon boards is as useless as stale bread, and is in fact as harmful as stale bread. Here’s how production tracking software based on Industry 4.0 principles can get you accurate and instant data on your Andon boards. Stale data on Andon boards is as useless […]