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Downtimes

What is Downtimes?​

Downtimes is where you configure downtime categories (reasons) and general downtime settings.

Access: Settings → Downtimes

Who Can Manage: Managers, Executives, IT Admins

General Downtime Settings​

Access: Settings → Downtimes → General

Key Settings:

1. Microstop Duration (seconds)​

Purpose: Threshold separating microstops from long downtime.

Configuration:

  • Enter duration in seconds (e.g., 60)
  • Default: 60 seconds

Impact:

  • Downtime < threshold: Categorized as "Microstop"
  • Downtime ≥ threshold: Categorized as "Long Downtime"

Reporting:

  • Microstops typically excluded from downtime reports
  • Long downtime requires categorization

2. Downtime List Filter (seconds)​

Purpose: Hide very short downtime events from operator categorization list.

Configuration:

  • Enter duration in seconds (e.g., 30)
  • Default: 30 seconds

Impact:

  • Downtime < filter: Hidden from operator's categorization list on tablet
  • Prevents operators from being prompted to categorize very short stops

Example:

Downtime List Filter: 30 seconds

5-second stop: Hidden (not prompted)
45-second stop: Shown (operator can categorize)

3. Unattended Inactive Threshold (minutes)​

Purpose: For unattended shifts, determines when idle time becomes unscheduled.

Configuration:

  • Enter duration in minutes (e.g., 30)
  • Default: 30 minutes

Impact:

  • During unattended shifts, if machine idle > threshold:
    • Time becomes unscheduled (doesn't affect Availability)
  • If machine idle < threshold:
    • Time remains scheduled (affects Availability)

See Also: Machine Schedules and Understanding Your Data Guide

4. Exclude Planned Downtime from Production Metrics​

Purpose: Exclude planned downtime (breaks, PM, etc.) from Availability and Performance calculations.

Configuration: Toggle on/off

Impact When Enabled:

  • Planned downtime subtracted from scheduled time
  • Does not hurt Availability or Performance
  • Still included in Quality calculation

Impact When Disabled:

  • All downtime (planned and unplanned) affects Availability equally

Example:

Scheduled Time: 8 hours (480 minutes)
Planned Break: 30 minutes
Planned Maintenance: 60 minutes

If Enabled:
Scheduled Time = 480 - 30 - 60 = 390 minutes

If Disabled:
Scheduled Time = 480 minutes (breaks/PM hurt Availability)

General Downtime Settings

Downtime Categories​

Access: Settings → Downtimes → Downtime Categories

Purpose: Define reasons for downtime that operators select on tablets.

See Also: Downtime & Quality Guide for comprehensive guide

Creating Downtime Categories​

Step-by-Step:

  1. Navigate to Settings → Downtimes → Downtime Categories
  2. Click "Add Category"
  3. Enter Category Name
  4. Select Planned/Unplanned Behavior:
    • Planned or Unplanned: Operator chooses
    • Unplanned: Always unplanned
    • Planned: Always planned
    • Planned with Limit: Planned up to X minutes, then unplanned
  5. Select Color (for visual identification)
  6. Click "Save"

Creating Hierarchical Categories​

Purpose: Nest categories for more specific root cause tracking.

Format: Use pipe (|) separator

Example:

Parent Category: Tooling
Child Category: Tooling | Tool Change
Grandchild Category: Tooling | Tool Change | End of Life

Steps:

  1. Create parent first: Tooling
  2. Create child: Tooling | Tool Change (note the space before and after |)
  3. Create grandchild: Tooling | Tool Change | End of Life

Important: You must create each level separately.

In Settings, there is an example showing the correct format with the vertical space bar character (|).

Planned with Limit​

Purpose: Mark downtime as planned up to a certain duration, then unplanned if it exceeds.

Example:

Category: Operator Break
Behavior: Planned with Limit
Limit: 15 minutes

Scenario:
Break duration: 10 minutes → Planned (OK)
Break duration: 20 minutes → 15 min planned, 5 min unplanned (excess)

Use Case: Allow reasonable breaks without affecting OEE, but flag excessive breaks.

Colors​

Purpose: Visual identification on tablets, timelines, and reports.

Best Practice:

  • Use consistent colors for related categories
  • Example: All "Maintenance" categories = orange, all "Material" categories = blue

Operator View: Colors appear on:

  • Operator Dashboard (tablet)
  • Timeline visualization
  • Downtime reports

Assigning Categories to Machine Groups​

When creating/editing Machine Groups:

  • Select which downtime categories apply to that group
  • Only selected categories appear on tablets for machines in that group

Example:

Group: CNC Mills
Categories: Tool Change, Setup, Material Unavailable, Maintenance

Group: Manual Welding
Categories: Waiting for Welder, Material Unavailable, Electrode Change

Operators on CNC Mills only see the 4 categories relevant to mills.

Downtime Categories list and creation form