Manufacturing and industrial
Downtime and scrap, counted live
Every stop and scrapped part read straight from your machines and shop-floor system.
Plant 2, week 38
Line counts through 07:00
OEE, line 3
71%
availability is the binding loss
Scrap rate, week60% from part 77312.4%
Schedule attainmentagainst the released plan94%
Orders held by qualitysame characteristic3
Line 3 OEE by shiftTue 2nd · 47%
Line 3 this weekLargest loss first
Changeover is the largest loss again
Line 3 · 6.1 hours this weekTop loss
Line 3 · 6.1 hours this weekTop loss
Material starvation clustered on one shift
2nd shift · three occurrencesPattern
2nd shift · three occurrencesPattern
Quality hold on order 44120
Characteristic 4 · awaiting dispositionOpen
Characteristic 4 · awaiting dispositionOpen
Show where the hours went
Every lost hour on the line, with its cause, so the same shifts can ship more.
- Minor stopsPauses under two minutes counted from the machine’s own signals.
- Planned downtime excludedBreaks, meetings and scheduled maintenance reported on their own.
- Changeover clockMeasured from the last good part to the first good part, by product pair.
Line 3, week 38
Planned time, less the downtime, speed and quality lossesOEE 71%
Planned time, less the downtime, speed and quality lossesOEE 71%
Changeover6.1 h
Unplanned maintenance3.8 h
Material starvation2.2 h
Minor stops1.6 h
Unplanned maintenance and starvation together cost 6.0 hours, as much as changeover.
Follow a work order from release to the dock
Each operation signed off at the station, so anyone can see where an order stands.
- Split lotsGood pieces move on while the held ones wait for a quality decision.
- TraceabilityLot, operation, operator and measurement recorded together.
- Certificates at shipCertificates of conformance generated from the recorded measurements.
Work order 44120
Line 3 · 1,200 pcs · customer ship date Sep 22Held by quality
Line 3 · 1,200 pcs · customer ship date Sep 22Held by quality
OpReleased Tue Sep 15 · 1,224 blanksGoodScrapStatus
10Rough boreBore cell 3A · signed Tue 22:40Good1,218Scrap6Signed
20Finish boreBore cell 3B · held Wed 15:40Characteristic 4 · 12.03 mm on a 12.02 limitGood820Scrap12140 held
30Deburr and washWasher 2 · since Thu 05:30Good300Scrap0Running
40Final inspectionCMM 1Good0Scrap0Waiting
Still to run at op 20
246 pcsDisposition due
Fri Sep 18Short if scrapped
134 pcsNumbers the line lead trusts
Answers for the 07:00 meeting, read straight off the line.
Line 3 stop captureOn change
Subscribe to 1,284 tags on Line 3 over OPC UA
Line 3 · Op 20 stopped at 14:02:11
Line 3 · Op 20 stopped at 14:02:11
Turn state changes into stop events
11 stops so far this shift
11 stops so far this shift
3One stop has no reason code
Held for the line lead to pick a cause
Held for the line lead to pick a cause
4Write each stop to the downtime table
Shift, line, cause and minutes
Shift, line, cause and minutes
Older lines without a tag server send a file instead.
From the machines to the ERP
Machine stops and finished operations posted to each order in your ERP.
SAPERP
NetSuiteERP
EpicorERP
IgnitionMachine monitoring
OPC UAMachine data
MQTTSensor messaging
KepwareMachine connectors
ExcelProduction logs
Point to the line losing the most hours
Its machine data and orders shape the first project, at a fixed price.