Case study · Production plant

Downtime reasons are no longer guessed at shift end — they are entered on the spot

A system where operators start work orders and enter downtime reasons and scrap on touch kiosks at each machine, and these entries are combined with SCADA machine data into live efficiency (OEE).

Before

Whether a machine was running could be seen from the PLC, but not why it stopped. Downtime reasons were written on paper at shift end, as far as anyone remembered.

Work orders, output quantities and scrap were collected on separate forms and keyed into the system the next day. Planning saw the real situation a day late.

What we built

Kiosk at the machineThe operator logs in with a badge, picks the work order by barcode and starts it; the screen has large buttons and works with gloves on.

Downtime reason requiredWhen SCADA detects that the machine has stopped, the kiosk asks for the reason; the stop cannot be closed without one. Reasons such as breakdown, waiting for material, setup and mould change are picked from a fixed list.

Quantity and scrapCounter data comes from the PLC automatically; scrap quantity and scrap reason are entered by the operator on the kiosk.

Live dashboardMachine data and operator entries are combined into OEE, downtime breakdown and work-order progress per machine, line and shift on the screen in the production office.

After

Why and for how long machines stop is recorded at the source, immediately. The 3 reasons causing the most loss became visible within the first month.

Planning sees work-order status in real time instead of the next day; the paper production form has been dropped.

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