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Leanworx captures every machine stoppage automatically, straight from your CNC controllers. See exactly when each machine stopped, for how long and why, find the causes that cost you the most hours, and cut downtime shift after shift.
Automatic machine downtime tracking for Fanuc, Siemens, Mitsubishi, Haas and Brother controllers.
Customers report up to 30% less machine downtime, including RBD Engineers and Zenith Precision.
Demo data for illustration.
Detects stoppages directly from the controllers already on your machines
Downtime tracking software records every time a machine stops producing, automatically and in real time. It captures the exact start time, end time and duration of each stoppage, lets operators tag the reason, and ranks the causes by lost hours, so manufacturers can see where production time goes and reduce downtime systematically.
Without it, downtime is tracked on paper or in a machine downtime log. Long breakdowns usually get written down. Short stops, waiting for material, slow changeovers and the ten minutes lost at every shift change usually do not, and together they are often the biggest loss on the shop floor.
Machine downtime tracking software takes the stoppage times straight from the CNC controller, so nothing is missed and nothing is rounded off. The result is a true picture of the causes of downtime in manufacturing in your own plant, not a guess.
Everything you need to measure, understand and reduce machine downtime.
The moment a machine stops, Leanworx records it from the controller with exact start and end times. Short stops that nobody would write down are included.
Operators tag the reason, such as breakdown, tool change, no material or no operator, from a simple list. Your reason list matches how your shop actually works.
Causes are ranked by hours lost for every machine, shift and day, so maintenance and production teams fix the biggest losses first.
Separate planned stops like scheduled maintenance from unplanned losses like breakdowns, and track unplanned downtime as its own target. See our unplanned downtime guide.
Compare downtime by shift, operator and machine. Night shifts get the same live tracking as day shifts, which is often where the biggest gains are.
See which machines break down most often and for how long, and spot patterns before they become major failures. Read our guide to machine breakdown analysis.
Downtime feeds straight into availability and OEE, so every minute recovered shows up in your efficiency numbers.
Daily downtime reports are generated automatically, and live status is shown on andon boards and phones so the right person responds quickly.
Real screens from Leanworx: the downtime views your supervisors and maintenance teams use every shift.
The usual suspects in CNC machine shops, and how tracking each one turns it into something you can fix.
| Downtime reason | Type | What tracking reveals |
|---|---|---|
| Breakdowns | Unplanned | Which machines fail most, how long repairs take, and where preventive maintenance would pay off |
| Setup and changeover | Planned | Actual setup time per job, so changeovers can be standardised and shortened |
| Tool change | Planned or unplanned | Unexpected tool breakage versus scheduled changes, by machine and part |
| No material | Unplanned | How much production planning and material flow cost in idle machine hours |
| No operator | Unplanned | Machines left idle at breaks and shift changes, and where staffing falls short |
| Waiting for inspection | Unplanned | Time lost waiting for first-piece approval or quality checks |
| Program or setup issues | Unplanned | Programs and parts that repeatedly stop the machine |
Go deeper with causes of downtime in manufacturing, 5 ways to reduce machine downtime and how one plant eliminated downtime at shift change.
Three steps from a paper downtime log to live, accurate downtime data.
Leanworx reads machine status from each controller over your shop network. Part programs and operator routines stay exactly the same. Older machines can be connected through an IoT device.
Every stop is recorded with its exact duration. Operators tag the reason at the machine in a few seconds, so each minute of downtime has a cause attached.
The downtime Pareto shows which reasons cost the most hours. Fix those, watch the numbers move, then move on to the next one.
Why paper logs and spreadsheets miss most of your downtime.
| Paper log or Excel | Leanworx | |
|---|---|---|
| Short stops | Almost never recorded | Captured automatically |
| Start and end times | Estimated and rounded | Exact, from the controller |
| Downtime reasons | Often missing or "other" | Tagged at the machine, every stop |
| When you see it | Next day, if at all | Live, while the machine is stopped |
| Analysis | Hours of spreadsheet work | Pareto and reports generated automatically |
| Night shift | Depends on what gets reported | Same accurate data, every shift |
A short checklist for comparing equipment downtime tracking software, and how Leanworx measures up.
| What to look for | Why it matters | Leanworx |
|---|---|---|
| Automatic stoppage capture | Manual entry misses short stops and rounds off the rest | Stoppages read directly from the CNC controller |
| Quick reason entry | If tagging a reason is slow, operators skip it | Reasons picked from a simple list at the machine |
| Works with your machines | Mixed shops need one system for every controller | Fanuc, Siemens, Mitsubishi, Haas, Brother, plus older machines via IoT |
| Real-time visibility | Downtime is cheapest to fix while it is happening | Live dashboards, andon screens and mobile access |
| Built-in analysis | Data only helps if it points to the next action | Downtime Pareto, shift comparisons and automatic reports |
| OEE included | Downtime is one part of overall efficiency | Availability, performance, quality and OEE calculated together |
| Fast setup | Long projects delay results | Customers report connecting a machine in about 10 minutes |
| Try before you buy | You should see your own data before committing | Free trial on your own machines |
A Leanworx customer replaced end-of-shift breakdown reports with live downtime data from their CNC machines and cut unscheduled breakdowns by 28%. Read the case study.
What manufacturers say after tracking downtime automatically.
Our downtime has decreased by 10%. The downtime, especially in the night shift, has reduced by more than 25%, which is a very, very important thing for us and is contributing a lot towards our productivity.
30% less machine downtime
With Leanworx we have been able to bring down our machine downtime by about 30% and increase in OEE by 10 to 15%, which is a huge saving. We have been getting fantastic results out of it. The reports that we generate every morning give us a good insight on the productivity and the performance of the operator as well as the machine.
Less downtime, exact data
It takes hardly 10 minutes for a person to connect to the machine. I can tell you that we are able to reduce the downtime, and we are able to improve productivity. The middle level supervisors and managers are also satisfied with the exact data that they are getting from the Leanworx system.
Shorter setups, more output
Overall, I see at least 8 to 10% efficiency improvement, especially OEE and the spindle run time. Setup time has been reduced and we can see an improvement of at least 10 to 12% production improvement.
30% to 55% spindle utilization
We've seen a lot of OEE improvements because now we can understand the parts, the spindle runtime, how effectively we are running. It's actually helped us to move from 3 shifts down to 2 shifts with more output. So we've moved from about 30% spindle utilization to now over 55% spindle utilization.
No more arguing about the data
After implementing Leanworx we are no longer discussing the quality of data or accuracy of data. Discussion revolves around what can be done to improve productivity. Looking at the benefit of utilizing and improving the equipment utilization, the incremental cost that we incur by paying the subscription is very small and it's a good value proposition from our point of view.
Numbers they can stand behind
When a customer asks, what is your OEE? We say 85%. Are we really at 85%? I don't think so. After installing Leanworx and improving systems, it's 88 when we finally checked the last time. So that's a substantial advantage.
Leanworx Lite gives smaller shops automatic downtime tracking, reason codes and daily reports without an IT team. Start free and connect your first machines yourself.
Try Leanworx free See plans and pricingFor 20 or more machines, or several plants, our team plans the rollout with you, sets up reason codes that match your process, and builds downtime dashboards for production and maintenance.
Book a walkthroughDowntime tracking software records every machine stoppage automatically, with exact start time, end time and duration. Operators add the reason, and the software ranks causes by lost hours so you can reduce downtime where it matters most.
Leanworx connects to each CNC controller over your shop network and reads machine status continuously. When a machine stops, the stoppage is recorded automatically and the operator tags the reason at the machine.
Planned downtime is scheduled in advance, such as preventive maintenance or planned changeovers. Unplanned downtime is unexpected, such as breakdowns, missing material or no operator. Leanworx tracks both separately so you can target unplanned losses.
In CNC machine shops the most common causes are breakdowns, setup and changeover, tool changes, waiting for material, no operator and waiting for inspection. Tracking them automatically shows which ones cost your plant the most.
Downtime is the total time a machine was not producing during planned production time. Downtime percentage is downtime divided by planned production time. Leanworx calculates it automatically, and you can try it yourself with our machine downtime calculator.
Downtime reduces availability, which is one of the three OEE factors. Every minute of downtime you recover increases availability and OEE. Leanworx calculates availability and OEE from the same data.
Results depend on your starting point. Leanworx customers report about 30% less machine downtime at RBD Engineers and over 25% less night-shift downtime at Zenith Precision.
Leanworx is a subscription priced by the number of machines, and you can try it free on your own machines first. See current plans on the pricing page.
Yes. In a small shop every idle machine hour hurts. Leanworx Lite is designed for job shops with a few machines and no dedicated IT team.
Connect a machine and watch every stoppage, reason and minute captured automatically. Your programs stay exactly as they are.
Try Leanworx free