Machine Downtime and Run Hours Recording

Running, idle and stopped time is worked out from the machine’s own readings. When a stop runs past a set number of minutes, the operator picks a reason at the panel from a short list.

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Counted from the machine, not a register

Running, idle and stopped are derived from readings the machine already produces. Nobody writes a time down, so nothing is filled in later from memory. The count is the same whether or not the supervisor is present.

What gets recorded

Run hours per machine

Hours the machine actually ran, by shift and by day. Two presses on the same line are compared on recorded hours, and not on what supervisors remember.

Reason picked at the panel

When a stop crosses the minutes you set, the operator chooses from a short list: die change, no material, power, breakdown. The list stays short on purpose.

Stoppages for the month

Reasons are counted across the month, so a reason that recurs forty times shows on a chart before it is discussed in a meeting. Patterns are counted, not argued.

Shift against shift

One machine can be read across three shifts, or this month against last. A pattern that only one shift produces becomes visible.

Who uses which number

Plant head

Downtime by machine and by reason, shift against shift. The review meeting starts from these figures.

Maintenance in-charge

Run hours by machine, and the stoppage reasons that keep returning.

Operator at the panel

A short reason list appears once the machine has been down past the set minutes.

FAQ

Frequently asked questions

How reliable are the stoppage reasons?

They depend on the operator choosing correctly, which is why the list is kept short. The duration itself is measured from the machine and is not typed in. It cannot be edited by hand.

Can it tell running from idle?

Yes, where the machine gives a signal that separates them, such as current draw, a run contact or a cycle pulse. What is available differs by machine. It is checked during the site visit.

Will these figures reach our ERP?

Yes. Run hours, downtime and consumption can be pushed into an ERP or maintenance package so that production planning reads them. Tally holds books and not machine logs, so a link there carries only the figures your accountant asks for.

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