Machine Downtime

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)