In a lot of shops, just machine downtime at shift changes and extended break times can account for up to 1.5 hours in each 8-hour shift, which is an astounding 18 % of available time. If you also have night time sleeping, you can easily hit 30 % downtime because of poor work ethics. Production tracking with an Industry 4.0 based system can easily put a stop to this. All these machine downtimes reduce to almost zero in just 2 weeks after installing the system.
If you work 3 shifts of 8 hours each, and the operator starts production 30 minutes late stops 30 minutes in every shift, you lose 3 hours every day. That’s 13 % of the available capacity.
Just extending breaks by 15 minutes in each shift can cause of downtime of 3%. That’s a capacity reduction of 3%.
There are firms where there is zero production in the second half of the night shift. The operators are presumably sleeping, because there were no supervisors in the night shift. This means the machines are idle 18 % of the time out of a possible 22 working hours. Misuse of Feedrate Override, to compensate for machine downtime
Feedrate override misuse is typically done to accelerate parts production to make up for downtime cause by other work ethics issues. This can result in reduced tool life and poor parts quality because of poor surface finish in finishing operations.
What’s the solution ? Leanworx has reports that shows all these 4 issues. Just print the reports every day for all machines and put them up on the shop floor notice board. So everyone knows who the slackers are. The problems just vanish automatically. No talking to people, no nasty conversations.
All machine downtimes caused by work ethics issues, between 10 and 30 % of the total available time, reduce to zero in just 2 weeks.
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