How Reason Codes Help Reduce Machine Downtime
By Paul Hogendorn
The worst enemy of any manufacturer is machine downtime. How to control and mitigate downtime is a constant battle for manufacturers trying to increase efficiency and maintain peak production. At FreePoint, through machine monitoring and production tracking technologies, we work with manufacturers to minimize downtime as much as possible, while maximizing machine output.
One of the ways we help manufacturers control their machine downtime is with Reason Codes, the backbone of downtime narration in our ShiftWorx platform. When a machine becomes idle, operators can apply a reason code to categorize that downtime period. Rather than seeing a machine offline for 20 minutes with no explanation, plant managers can see in real-time what the cause of the delay is— and address it. Those small increments of time add up, 10 minutes here or there can be worth over 6 figures in a year.
Using Reason Codes, you can:
- Diagnose Machine Downtime Causes and Apply Solutions
- Alert Decisions Makers in Real-Time to Plant Floor Issues
- Identify Machine Maintenance Needs
- Empower Employees to be Part of the Solution
Identify Downtime Causes
With reason codes, employees and managers can easily identify factors impacting machine downtime. Whether the reason is “waiting on materials” or “needs repair”, everybody is made aware of what factors are contributing to delays— valuable data for plant managers seeking to increase efficiency and achieve seamless production in real time. If someone has transparency into delay causes, they are more motivated to solve the cause of the delay. This makes the overall process more efficient and engaging.
Keeping Everyone in the Know
Reason codes also help mitigate machine downtime with real-time alerts. When reduced productivity or machine delays are detected, notifications are sent to all devices connected to our ShiftWorx platform –through SMS or email. Real-time alerts increase response time to problems that impact production—meaning solutions are found faster, and the length as well as frequency of downtime can be decreased.
Identifying Downtime Patterns
By comparing actual performance to projected performance, you can benchmark productivity against past data to identify opportunities for improvement. A recurring reason code could indicate a machine issue in need of maintenance, or another machine consistently causing delays. Identifying these factors better positions plant managers to rectify them and prevent them from happening in the future.
It is important to understand that all data is good data. Even un-anticipated downtime, machine breakdowns or inefficient scheduling can give you crucial insight into your operation. When machine monitoring hardware works in tandem with data visualization, you can see every performance detail from any machine, regardless of industry or age of machine.
For more information, visit FreePoint at www.getfreepoint.com