Machine Downtime

Machine Downtime - Manufacturing Dashboard

High Level Design

Overview

As a manufacturing business, one of the main areas of focus is utilization of the production floor. In the case examined here, the factory works 24/7 and every production stop reduces the total units that can be produced and therefore undermines revenue and profitability. Understanding trends, main root causes and other insights from analyzing this data will enable the organization to focus on the most crucial improvements that need to be made.

Goals

Maximize production utilization in order to achieve higher profitability.

Objectives

  • Analyze the utilization rate for every period of time, error type and product type to figure out what should receive higher focus.
  • Understand total downtime in order to have a numeric reference that can be used to analyze trends and problematic areas.

KPI Architecture

Objectives KPIs Measures Data Source
Analyze the utilization rate for every period of time, error type and product type to figure out what should receive higher focus.

Understand total downtime in order to have a numeric reference that can be used to analyze trends and problematic areas.

 % of Utilization Utilization %/per unit type/per week –

(1440-avg([Unit_Day],sum([Duration (minutes)])))/1440

 Shop Floor Control\ProductionStops;Machines;Dates
Utilization distribution per day of week

(Day of week Utilization %)/ Utilization %

 Shop Floor Control\ProductionStops;Machines;Dates
Average downtime by hour AVG DOWNTIME by hours \per error type\

avg([Unit_Day],sum([Duration (minutes)]))/60

 Shop Floor Control\ProductionStops;ErrorType
Standard deviation of Downtime by hour StDev DOWNTIME by hours
StDev([Unit_Day],sum([Duration (minutes)]))/60		 Shop Floor Control\ProductionStops;ErrorType

Data Requirements

# Source Table Name Table Details (type, # rows, key fields)
1 Shop Floor Control ProductionStops Transaction Table
2 ErrorType Dimension Table, Key = Unit Id
3 Dates Dimension Table, Key = Date
4 Machines Dimension Table, Key = Error Type Id

Data Modeling (Elasticube Design)

Suggested data model for machine downtime analysis

Department

Manufacturing Supply Chain

Role

C-level Executive, VP, Director, Line Manager

Data Connectors

KPIs

Maintenance Costs, % of Utilization, Average downtime by hour

Implementation
Kit

The following resources will enable you to design your dashboard and data model with sample data and then apply it to your own data. Note that you will need to have a previously installed version of Sisense (you can use the free trial version if you’re not a customer).

Sample data and dashboard examples (direct download)

Documentation

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