Stamping Press Downtime Analysis

Stops are captured from the machine rather than logged after the fact, and the operator names the reason at the press while it is still fresh. Each reason carries duration, share of total downtime and occurrence count together, which is what makes Pareto prioritisation possible without exporting anything. The same record then re-reads seven ways: by state, by reason, by asset, by tool, by product, by department and by operator. Selections compose, so two reason codes can be isolated and then re-pivoted by operator.

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Capture
From the machine, automatically
Classification
Operator names the reason at the press
Reason codes
Configurable master list
Each row carries
Duration, share, occurrence count
Pivots
State, reason, asset, tool, product, department, operator

In the product

Ranked by duration, with share and occurrence count on the same row. The tabs re-read the same data.

State overviewBy reasonBy assetBy toolBy productBy departmentBy operator
219h 15m
Unplanned downtime, 30 days
Top 5 of 22 reasons
  • Power supply not available41h 23m
    18.9% · 16 stops
  • Coil loading22h 56m
    10.5% · 145 stops
  • Breakdown analysis17h 16m
    7.9% · 149 stops
  • Adjusting the setup15h 53m
    7.2% · 172 stops
  • Tool breakdown15h 28m
    7.1% · 27 stops

What it does

Automatic capture
Every state change is timestamped and recorded without anyone writing it down.
Reason at the machine
The operator classifies the stop on the panel already in front of them.
Pareto ranking
Duration, share and count on one row, ordered so the biggest loss is first.
Seven pivots
The same data re-reads by state, reason, asset, tool, product, department or operator.
Composable filters
Isolate two reason codes, then re-pivot by operator without leaving the view.
Planned and unplanned split
Scheduled downtime is separated from the losses that matter.

How it works

  1. Detect the stop

    The machine state changes and the clock starts, with no human involvement.

  2. Name the cause

    The operator selects a reason and can add a note.

  3. Rank and pivot

    Reasons order by duration, then the same set re-reads by any dimension.

Who this is for

  • A plant that knows total downtime but not its distribution.
  • A shop arguing about whether coil loading or tool breakdown costs more.
  • A maintenance head who needs occurrence counts, not just hours.

Questions

Does an operator have to log every stop?
The stop is captured automatically. The operator only supplies the reason.
Can we add our own reason codes?
Yes. Reasons are a master list you maintain.
Can we see downtime for one tool across all presses?
Yes, by pivoting the same record by tool.
Is planned downtime counted against us?
No. Planned and unplanned are recorded separately.

Related

See it on your own presses.

We instrument one press, run it for a month, and show you the shift record against what you thought was happening.

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