Production and performance
Downtime and OEE
Every stop with its time, duration and cause, and an OEE you can explain.
- Availability
- 86 %
- 69 min stopped
- Performance
- 89 %
- vs standard
- Quality
- 96 %
- good product
OEE = availability × performance × quality = 74%
The problem
Short stops go unrecorded, but they add up
A five-minute jam at the fryer exit doesn't seem important. Repeated several times a shift, it's lost output nobody can explain or tackle, because it was never recorded.
In validation on the plant floor
Sound familiar?
- The downtime log only has the long stops.
- Causes are written from memory at the end of the shift.
- OEE, if it exists, is a number nobody can break down.
- Maintenance and production argue about why the line stopped.
What we ask first
Before proposing anything, we understand what happens on your line today.
- When the line stops, who finds out and how long does it take?
- Where is a five-minute stop recorded?
- Who decides the cause and who fixes it?
- Do you know today which stop cause costs you the most time per month?
How we approach it
We detect the stop from the real product flow or from a machine signal. The system records start and duration automatically; the supervisor only confirms the cause.
1. We define what counts as a stop
How many seconds without product count as a stop, and which stops are planned (changeovers, cleaning).
2. We record the stop on its own
Start time and duration are logged without anyone writing anything.
3. We confirm the cause on the floor
The supervisor picks the cause from a list agreed with your team, on a tablet or phone.
4. We break down OEE
Availability, performance and quality by line, shift and product, each with its source.
What it takes
Software
- Automatic stop log with a cause list
- OEE calculation by line, shift and product
- Downtime analysis by cause
Plant equipment
- The line's existing counting source (camera or machine signal)
- Tablet or phone to confirm causes
If the line already has a run/stop signal it can be used; if not, stops are detected from product flow. This is defined during technical design.
Who uses the information
- Shift supervisor
- Confirms causes while the stop is still fresh.
- Maintenance
- Sees which equipment stops most and for how long.
- Plant manager
- Knows which cause cost the most time this week.
- Continuous improvement
- Chooses the next problem to tackle with data.
Decisions it supports
- 01Which stop cause to tackle first.
- 02Whether a problem is equipment, material or method.
- 03When to schedule preventive maintenance on critical equipment.
- 04How to plan changeovers to lose less time.
How value is measured
We measure before and after, on your line. Value is shown with your data, not promises.
- Unplanned stop minutes per shift
- Baseline measured in the first weeks and compared after each action.
- Stops without a recorded cause
- Share of stops with a confirmed cause, week by week.
- OEE and its three components
- Calculated with the same rule before and after.
What it connects to
Stops come from the count; long ones trigger alerts and all of them feed the loss-by-cause report.
- Automated countingA camera over the belt counts every piece and records when product stops flowing.→
- Alerts and follow-upThe problem reaches the right person in the moment, and its follow-up is recorded.→
- Reporting and operational intelligenceWhat happened in the plant, ranked by what cost the most, without building spreadsheets.→
Let's start with one problem.
Tell us what's costing you most today. We review it with you, show how we'd solve it and estimate its value together.