Downtime Tracking
Malisko Engineering, Inc was asked to provide a Downtime Tracking System to pinpoint sources of production inefficiencies and assist with prioritizing corrective maintenance planning. The System was designed, programmed, tested, installed, and validated for a worldwide leading manufacturer of Infant and Adult Nutritional Products.
Goals
- Identify & Quantify Sources of Production Line Downtime
- Provide "Root Cause" Information for Downtime
- Provide both Real-time & Historic Data
- Analysis via SQL (Structured Query Language) Database
- Malisko Engineering, Inc. was involved in every aspect of this Project, from Conception and Capital Budgeting to Real Time Production
Challenges
- Identify Possible Sources of Downtime Based on Empirical Study
- Use Existing Sensors & Devices Only
- Aggressive Project Schedule
- Overcome Plant's Skepticism Due to Inaccuracies of Downtime Tracking Systems Previously Supplied by Others
System Features
- Monitor Line from Can Depalletizer Through High-Speed Fillers/Seamers
- Forty-two (42) Unique Causes Monitored
- Log to Microsoft Access Database Each Line Stoppage Occurrence with the Following:
- Root Cause
- Date & Time of Occurrence
- Elapsed Time of Stoppage
- Batch Code
- Production Line Number
- Display Real-time Table of the Causes
- By Production Line Number
- By Equipment Section
- Accumulative Number of Occurrences of Each Cause for the Batch
- Accumulative Downtime of Each Cause for the Batch
- Display Real-time Pareto Charts by Production Line Number & Equipment Section
- Display Real-time Bar Charts of Accumulative Downtime of Each Cause by Line Section
- Automatically Generate Hardcopy Downtime Summary Reports & Pareto Charts at the End of Each Batch
- Can Generate Reports & Charts on Demand
Project Successes
- Production & Maintenance Groups Immediately Started Using the Information
- Efficiency Improvements were Quickly made by Addressing the Primary Culprits of Downtime
- Achieved ALL Goals
- System Installed in 1996 & Continues to be Used