Downtime Tracking System - Effective Tool For Improving Performance

Downtime Tracking System

Malisko Engineering, Inc. was asked to provide a Downtime Tracking and Data Collection System to a multi-national Food & Beverage Company. The System monitors 21 Tablet Presses. Operators choose from 28 standard downtime cause codes. Maintenance subcategory codes are also entered and recorded. Each downtime cause is logged to a database with time/date stamp, line #, operator, product, cause code(s) and duration.

Goals:

  • Accurately capture machine downtime causes,
  • Create timely reporting of downtime and maintenance causes,
  • Eliminate manual data entry by electronically logging downtime causes into corporate-wide efficiency tracking/reporting system.

System Features:

  • Operator/Maintenance enters PIN code(s)- allowing for security system and tracking,
  • Downtime Events are recorded by SAP asset #'s and by a physical location,
  • Integrated with the existing Batch system to automatically acquire Product Name and Flavor for each tablet press,
  • Counts number of tablets per minute,
  • Calculates an accumulated RUNTIME for each press,
  • Mechanics can log in/out to work on presses, downtime is still logged and then auto-recorded in the database,
  • Downtime database automatically transfers the collected data into the Corporate Efficiency Tracking System,
  • Downtime is monitored, tracked and subdivided into more detailed categories for the plant's maintenance department. This allows them to analyze and report downtime specifics to management.

Engineering Tasks & Services

Downtime Tracking System
  • Involved in developing the concept, architecture, capital budgeting and helped reduce the original overall cost of the project,
  • Assisted in the selection of instrumentation and electrical equipment,
  • Used an existing PLC and integrated the new system with an existing system,
  • Designed, programmed, tested, verified wiring and validated the downtime tracking system,
  • Production support,
  • Integrated Intellution, ACCESS database, Device-Net, operator touch screens, client-specific network, and Allen-Bradley SLC5/05 PLC (Ethernet),
  • Production and Maintenance training with a User's Manual for the System.