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Identifying the real reasons and true extent of production stoppages, equipment constraints or bottlenecks caused by machine downtime can reduce costs and greatly improve manufacturing efficiency. Prodigy's specialised machine utilisation and downtime monitoring facility automates equipment & machine downtime data acquisition, reporting and analysis for optimisation of uptime, output and return on investment.
Downtime Tracking
- Optimise uptime
- Minimise downtime
- Improve efficiency
- Increase profitability
- View & filter events
- Unlimited events
- Event sub-categories
- Split downtime events
- Add user comments
- Machine set-up codes
- Manual override
- Complex event detection
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The Prodigy Downtime Monitoring facility has been specifically designed for the automatic capture of machine utilisation performance data in real time from production equipment. By automating data acquisition, analysis and reporting it minimises labour costs and makes management information available instantly on demand.
Downtime information at a glanceThe facility runs on an industrial PC with Microsoft Windows operating system. A typical system has customisable multi layered screen displays that give a dynamic graphical presentation of the production process. An overview display of the entire production area with machines colour coded (green for running, red for stopped, yellow for changeover etc.) gives the user an instant update on the production process at a glance.
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| Plant overview example |
The screenshot below shows three machines which, on the live system, are animated when running. In this example each machine has production and scrap counters and a realtime trend showing actual versus target production rates. Any number of display screens or levels can be provided to represent even the most complex of operations.
Automatic OEE CalculationProdigy can automatically calculate current machine efficiency, production rates, scrap counts, downtime as well as OEE - Overall Equipment Effectiveness. Find out more about OEE, using Prodigy for automatic OEE calculation and download a free OEE calculator spreadsheet.
Problem areas can be highlighted through colour change, flashing graphics and alarms. Any number of alarms can be configured to warn of problems that occur. Alarms appear on the display alarm banner and can be distributed to annunciators and beacons as well as by email and via SMS messaging to mobile cellular phones.
Automatic Downtime Data AcquisitionProdigy can simultaneously monitor any number of machines or production areas. When a stoppage occurs, it starts accumulating downtime. If the stoppage is too long an interlock can be activated to prevent a machine from being restarted before a downtime reason has been entered. This ensures that a reason is entered for the downtime event. The length of time before the interlock is activated can be set to suit the circumstances.
Any machine downtime logged before the interlock activates is recorded as short stoppage time. Short stoppages are often disregarded as insignificant and cannot be accurately determined without a real time system.
When accurately recorded short stoppage time is often found to be a major factor in lost production
Versatile Operator Interface TerminalsWherever possible machine downtime reasons are captured automatically from PLC's (Programmable Logic Controllers) or associated control equipment. Where this is not possible operators can input them using the system PC or specially designed DTM 02 Machine Utilisation and Down Time Monitor Terminals.
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| Shopfloor Terminals & Barcode Reader |
These rugged operator interface terminals can be conveniently situated adjacent to the machines being monitored eliminating the need for operators to leave the production area. They provide all the operator controls required and can used to input operator/batch/order codes and to view information such as current/target production rates. This provides valuable feedback to the shop floor.
Terminals feature multi-line back lit alpha numeric LCD displays and have customisable wipe clean fascias suitable for hygienic applications. Each terminal can serve one or more machines and function keys are configurable to suit each application. You can download specification sheets on the range of shopfloor terminals and hardware here. The Prodigy Shop Floor Terminal Support facility is required to enable the use of operator terminals.
Any number of downtime reasons or codes can be handled with sub codes to help manage the data more effectively. Special machine codes that allow machine set up times to be tracked without interference from the downtime tracking system are also supported. If a machine is stopped due to more than one reason then multiple reasons can be assigned to the event sequentially.
Comments can be entered against downtime events, either when the downtime occurs or at a later time. Comments are used to provide specific information about the downtime reason and can help with fault identification, diagnosis and repair etc.
Prodigy also supports barcode scanners for easy input of data and product tracking.
Large scale data displays can be used in production areas to display actual and target production rates to inform and motivate staff to what must be done to achieve shift or daily targets.
As well as monitoring individual machines or processes, Prodigy can be configured to monitor linked production lines, handling the more complex requirements of inter machine buffering, materials re-stocking and cascaded interlocks.
Downtime Reporting and AnalysisReal time data capture means that downtime reporting is instant with reports covering any required period of recorded data. This allows fast analysis of downtime or production data for any desired period such as the last batch, shift, day, month etc. Direct comparisons can be easily made between different shifts, production lines and products.
Collected data is stored directly in a Microsoft Access compatible database and can be shared with a wide range of standard PC applications. This allows exchange of information with production planning systems and enterprise information systems to feed back what has been achieved.
Reports can be produced on demand, at batch end or to any timed period. Delivery can be to a printer, by email, fax, published to the internet or via SMS message to any mobile phone.
Downtime Viewer and Downtime Overviewer
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| Downtime Viewer, Overviewer and Quick Stats |
Relevant information is key to maximising efficiency and Prodigy provides powerful tools to extract the information you need. Downtime Viewer lets you analyse the downtime of any machine. Downtime events are presented in tabular format. You can sort on time, duration, type and reason. Data can be edited allowing downtime reasons to be assigned, split, combined or amended. Comments can also be added to events or amended.
Downtime Viewer has a Quick Statistics page that displays the totals and percentages for downtime, plus top downtime reasons by duration, by number of events and by level.
Downtime Overviewer allows quick comparison between machines in a visual format. The status of any number of machines is displayed as time lines with colour indicating the state of the machine. The accumulated time of each machine state can also be displayed. This type of visual presentation can highlight anomolies and patterns that may not otherwise be identified.
Optimise MaintenanceBy also utilising Prodigy's On Line Maintenance facility you can quickly access the information needed to help rectify production stoppages or even prevent them happening in the first place. The On Line Maintenance facility allows multi media files to be stored on the system for fast access via on screen icons or buttons. Important information in the form of text, diagrams, images, sound files or video footage can be made available instantly. This could include machine schematics, parts lists, supplier contact details, emergency advice etc. The facility can also useful as a training and reference aid for new operators.
As Prodigy continuously monitors machine states in real time it can be used to calculate the optimum time for maintenance to be done. The system can be configured to alert when a machine has run for a set time or number of cycles. This can ensure that money is not being wasted on over maintenance or reliability sacrificed due to under maintenance.
Frees Staff To Do More Value Added WorkNot only does a Prodigy downtime monitoring system provide you with accurate and timely information on the real causes of downtime to enable increased output. It also frees your supervisory personnel to do more value added work and production target information made available on the shop floor helps to motivate operators. Networking of Prodigy systems makes production and downtime information available enterprise wide if required, providing management with accurate information on which to make informed decisions.
With a Prodigy downtime monitoring system usually costing a small fraction of the capital value of the machines it monitors, implementation makes real financial sense.
Turnkey downtime monitoring systems designed to your requirements are available through a network of authorised Prodigy resellers. Please contact us for details of your local reseller.
Typical ApplicationsProdigy downtime monitoring can be applied to any type of manufacturing operation and is particularly useful where a factual analysis of stoppage reasons and times is wanted. Examples of typical applications include:
- Paint and plastic coating lines
- Production of wires and wire products
- Packaging lines
- Forges and presses
- Food Processing
- Extrusion monitoring
Read a Prodigy machine utilisation and downtime monitoring application summary here
Ask a question about this Prodigy facility.
Downtime Monitoring and Machine Utilisation - How much can it save you?
Implementing a downtime monitoring and machine utilisation system like Prodigy can help you identify the real reasons for lost production, reduce downtime and increase output. But how much could a system like this save you? To help you judge the potential savings we have prepared a document outlining the benefits and with an example worksheet to follow. There is also a spreadsheet that can automatically calculate the savings to be made - just input your own data.
Download the free downtime monitoring files.
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