how to calculate machine downtime percentage

Employees affected by downtime: An estimate of the percent of employees who would be unable to work due to shut down machinery. You're right, this can seem a bit complicated at first, but actually it isn't. To calculate system availability for a certain period of time, divide an asset’s total amount of uptime by the sum of total uptime and total downtime. an estimated percentage of downtime multiplied by the planned hours of operation for the machine and the hourly cost of a replacement or rental machine.3 This approach focuses on the failed machine alone and disregards any effect the failure may have on the system as a whole. The collected data is used to accurately calculate downtime, production rates, scrap count & reject rates, machine speeds as well as machine efficiency and OEE - Overall Equipment Effectiveness. In percentages, this is 0.69%. We hear you thinking: but how do you mark the time between different monitor statuses (OK, unconfirmed error and confirmed error)? Our website is also available in Dutch, French and German. Read a few of our customer use cases to see how companies from different markets use the Uptrends products. Downtime is considered the largest source of lost production time for manufacturing, which makes this an incredibly important metric. Ask Question ... 11 months ago. By tracking and analyzing production downtime, managers can identify production flow problems and develop action plans that focus on corrective and preventive measures. Hours of Downtime X Average Production Rate = # of Units Not Produced # of Units Not Produced X Gross Profit per Unit = Total Gross Losses So, let’s say that … The rest of the time the machine is in the running mode. The second thing to note down - after reaching the mechanic at what time machine issue is rectified and fixed. As described in the OEE Factors page, the OEE calculation begins with Planned Production Time.So first, exclude any Shift Time where there is no intention of running production (typically Breaks).. Revenue affected by downtime: An estimate of the percent of revenue lost due to machine downtime. Create a safe learning environment with digital maintenance checklists. I want to use the Pivot table to summarize the data, and calculate the uptime % of each month. As you probably already know, Downtime is any period of time when a machine is not in production (quite literally, down). an estimated percentage of downtime multiplied by the planned hours of operation for the machine and the hourly cost of a replacement or rental machine.3 This approach focuses on the failed machine alone and disregards any effect the failure may have on the system as a whole. For most manufacturers, downtime is the single largest source of lost production time. I have an excel which keeps the system downtime details of each issue. To calculate system availability for a certain period of time, divide an asset’s total amount of uptime by the sum of total uptime and total downtime. Plant downtime = 1 – (Plant run time/Total available time to run or produce) 8. To convert .87 to a percent, simply multiple .87 by 100..87 × 100=87. ... For example, a machine in a job shop requires inputs of $400 an hour that produces parts with a value of $600: Efficiency = (600/400) * 100 = 150%. Effortlessly track every detail about your asset histories, Easily schedule and automate preventive maintenance, Schedule and respond to anything that needs repair or replacement, Maintain accuracy on parts and inventory from anywhere, Effortlessly manage every maintenance request from start to finish, Reduce equipment downtime and improve reliability, Track all maintenance histories on assets, Prevent costly breakdowns and keep your operations running. Incident downtime is only calculated during the business hours with the incident suspending outside of the contracted business hours. Hi All, I’m looking for assistance to help calculate incident down time relative to the hours of business operation. Now imagine how large these lost revenue figures can be if the downtime is higher or if the product is more profitable. DowntimeDB creates standard reports and charts for daily, weekly, monthly and yearly time periods. However, as visible as downtime often is, most companies significantly underestimate their true downtime, and over 80% of companies a… In percentages, this is … We divide 600 by 86,400, which is 0.0069. Plant run time = Total available time to run – scheduled and unscheduled downtime/stoppages. Planned downtime is downtime as scheduled for maintenance. In a 16 hour scheduled production day Machine A is capable of producing 16,000 good units. For that, a double-check needs to be performed. Copyright © 2007 -  2021  | Terms and Conditions | Privacy Policy | Licensed Patents |  Sitemap. When the uptime percentage is being calculated, please keep in mind that we include the total number of unknown seconds as well, and mark the unknown time as uptime. If a company is working only 8 hrs a shift,so does the hrs after shift also be calculated as breakdown hours OR only 8 hrs shift to be taken in calculation even if the breakdown last for complete 3 days. By using the Uptrends website, you consent to the use of cookies in accordance with our Cookie Policy. Unconfirmed error to OKThe time between the two measurements is being considered as up, because we are not sure there is an actual error. Downtime is any time the equipment is not available for production, including planned and unplanned downtime. Let's say we monitored a website during 24 hours (which translates to 86,400 seconds), and in that timeframe the website went down for 10 minutes (600 seconds). Planned Production Time. Divide the total number of units produced by the actual operating time to get the average production rate for your equipment. Once you’ve tracked equipment downtime with a CMMS and calculated the average losses due to this downtime, it’s time to begin thinking about how to reduce downtime. In a 16 hour scheduled production day Machine A is capable of producing 16,000 good units. Total number of seconds your website was monitored: 86,400. Estimate Savings from Reduction in Unscheduled Downtime. 2. This measure helps companies calculates the percentage of scheduled run time that is disrupted by unplanned machine downtime. Thus, resulting in 87 percent. The PC display acts as a 'shop floor overview' visualisation that gives the user an instant update on the production process at a glance. If you want to exclude the unknown time from the uptime calculation, you can retrieve the total number of uptime seconds to do your own calculation. Unconfirmed error to confirmed errorThe time between the two measurements is being considered as down, because the error is now confirmed. Calculate the Cost of Downtime IT projects, especially infrastructure projects can be challenging to get approved. Multiply the total downtime by your average production rate to find the total number of units you failed to produce during planned production hours. If your goal is to get to 80%, these things can be included, or not, to arrive at the target. Planned uptime = service hours – planned downtime. Presenting your answer as 87% or 87 percent is acceptable. Note that unplanned machine downtime does not include downtime for preventive maintenance or unscheduled use. Note that unplanned machine downtime does not include downtime for preventive maintenance or unscheduled use. On a particular day Machine A recorded downtime of 2 hours (e.g. When you pause a monitor, this time is being registered as unknown. A %RAV between 2 and 5 percent allows maintenance planners to estimate the amount of money necessary for equipment maintenance because that amount of money shouldn’t exceed the facility’s %RAV. This website uses cookies to ensure you get the best experience. Although your website is not actually down, it will show an uptime of less than 100% because the performance condition was not met. How to Calculate Machine Downtime Rate . In this way, tracking downtime becomes a method of mapping out the overall health of each individual part of an organization’s production. Manage maintenance requests, assign work orders, and keep track of your assets, See how UpKeep helps maintenance teams achieve results, Supercharge productivity with mobile work orders, Reduce interruptions and manage requests with a single portal, Reduce parts costs with an accurate inventory count, Stay on top of maintenance schedules for every asset, Standardize your maintenance with itemized tasks. Availability = uptime ÷ (uptime + downtime) Here’s an example of the system availability formula in action: One of your top production assets ran for 100 hours last month. Formula: Shift Length − Breaks Example: 480 minutes − 60 minutes = 420 minutes Run Time. This measure helps companies calculates the percentage of scheduled run time that is disrupted by unplanned machine downtime. It’s often measured by “Nines.” Let’s see how they translate to downtime for 30 days: A-Z. The most significant benefit of registering breakdown reasons is that it enables you to understand the reasons behind your availability losses. The counterpart of that is downtime. It shows the time or percentage the service was unavailable. Aim for unscheduled downtime to be 10% or less. An SLA level of 99.99% for example equates to 52 minutes and 36 seconds of downtime per year. As we’ve already discussed, tracking equipment downtime provides a health map of a facility’s production and manufacturing environment. Production downtime translates into an under utilization of capacity that impacts the bottom line. Pretty simple, ain't it? See your entire space at a glance and optimize maintenance planning. Formula: Shift Length − Breaks Example: 480 minutes − 60 minutes = 420 minutes Run Time. The collected data is used to accurately calculate downtime, production rates, scrap count & reject rates, machine speeds as well as machine efficiency and OEE - Overall Equipment Effectiveness. I am making a script that runs via cron every minute to check the uptime of a remote server. Confirmed error to unconfirmed errorThe time between the two measurements is being considered as down, because the monitor is still in an error condition. The problem is, from Pivot table, I can only get the total down time, total downtime %, and the total uptime. Typically, this term refers to unexpected downtime that accumulates any time the production process stops. Actual Uptime Minutes ÷ Planned Runtime Minutes × 100 = Production Uptime Percentage In the case of our hypothetical widget machine, the calculation would be 365 Actual Uptime Minutes ÷ 480 Scheduled Runtime Minutes × 100 = 76% Production Uptime Percentage. It’s easy to see why this is so important to track and fix as quickly as possible. Labor as a percentage … It shows the time or percentage the service is up and operational. The way we calculate uptime is easy to understand: we take the number of seconds that your monitor was down (in a certain time frame), and divide this by the total number of seconds your monitor was being monitored during that time frame. Following this equation, if we produce 10 units per hour and we make a profit of $50.00 per unit, that means each hour is worth $500. Please keep in mind that all errors are taken into account when we calculate downtime. Availability = uptime ÷ (uptime + … One way to calculate the cost of equipment downtime is to look at the loss of revenue over downtime periods. Assume Machine A is a single product machine and is capable of producing 1,000 units every hour (Machine Capability). If there were 82 minutes of unplanned downtime during the shift, then the machine would’ve actually run for 338 minutes. Below the OEE calculator, we discuss the formulas and details of the OEE calculations. This is why during downtime, you always see a pattern of unconfirmed errors and confirmed errors in your website monitoring dashboards. Popular. Assume Machine A is a single product machine and is capable of producing 1,000 units every hour (Machine Capability). 2.0 DOWN TIME:(B) The available hours per shift is 8 hrs. What is Estimated Plant Replacement Value a? computerized maintenance management system (CMMS), Investing in a robust CMMS that can track a large variety of fields (maintenance shift, location of issues, downtime reasons, accurate downtime tracking), Ensuring a well-documented preventive/predictive (PM/PdM) maintenance schedule with high, Installing and maintaining sensor equipment to utilize, Documenting maintenance processes to resolve downtime events swiftly, Backing up important systems that can be lost to errors (e.g. Some other benefits to tracking and fixing downtime can be: Equipment downtime refers to any time that equipment involved in the production or manufacturing process isn’t running, Tracking downtime acts as a diagnostic tool for a facility’s production health, Downtime can cost an organization massive amounts of money in lost revenue, Reducing downtime can involve investing in a CMMS, documenting maintenance work, and creating a PM or PdM program, 10880 Willshire Blvd, Los Angeles, CA 90024. PLC systems), Better prioritization of maintenance staff (lowered amount of unplanned downtime events means more time on PM/PdM schedules), Gives managers an inside look into necessary replacement and repair priorities, More accurate implementation of corrective maintenance tasks, Raises profit and lowers maintenance costs (especially on replacement equipment in emergency cases), Higher machine uptime, efficiency, and reliability (due to PM/PdM plans being effectively implemented), Planned Maintenance Percentage (PMP) Explained. To define the uptime and downtime percentages, we perform the following calculation: Total number of seconds your website was down: 600 seconds.Total number of seconds your website was monitored: 86,400. What is Downtime Cost? As described in the OEE Factors page, the OEE calculation begins with Planned Production Time.So first, exclude any Shift Time where there is no intention of running production (typically Breaks).. Method to calculate downtime percentage. The calculator below provides an easy way to calculate the downtime allowance as a time period based on a provided uptime percentage. This has been a deliberate choice, because a lot of customers requested this. Available on all Uptrends plans. Should you classify a lack of orders or a lack of raw material as planned downtime? One way to calculate the cost of equipment downtime is to look at the loss of revenue over downtime periods. For that, a double-check needs to be performed. Calculate needle downtime in the percentage of total hours worked by dividing 80 minutes by 8 hours. Let's jump into an example. It receives a high level of attention since equipment failures and breakdowns are highly visible. A world class example of equipment downtime is anything less than 10%, meaning that a facility’s equipment should be running at 90% availability or greater. On the other hand, a low maintenance downtime figure can indicate a generally healthy production environment. Generate purchase orders and automatically update your inventory. Various tiles in your dashboards allow you to select these metrics. ... x Percentage of Impact x Hours of Downtime. 10minutes machine breakdown and 20 minutes for change over-total down time is 30minutes Down time in % 6.25% and available time is 93.75%(B) 3.0 QUALITY(C) REJECTED PARTS PERCENTAGE :SAY 1% OK PARTS =99% (C) THE OEE IS A*B*C = 87.5% * 93.75%* 99%=81.2% The bottom line on planned maintenance percentage Measuring, analyzing, and improving planned maintenance percentage can have a huge domino effect on your entire facility. For example, a high equipment downtime figure might mean that preventive maintenance isn’t being performed properly or that there are problems with how production is set up. Also known as: Service Outage Duration Reducing downtime with planned maintenance leads to more uptime, increased production, and less money lost from stoppages. Account for the product cost of the downed machine by determining the direct value loss due to the downtime. Machine Downtime Rate is any time the equipment is not available for production, including planned and unplanned downtime. equipment breakdown, waiting on materials etc..). Equipment downtime refers to the amount of time that equipment is not operating, whether that’s a result of unplanned equipment failure (like a fault or broken part) or planned downtime (like necessary downtime for preventive maintenance). While it can seem expensive to track downtime with a computerized maintenance management system (CMMS), there’s a potentially far larger amount of money saved on knowing where issues lie and eliminating them. Automatically generate work orders and assign to technicians. Once we have calculated the cost of Downtime, we can calculate the cost savings from reducing Unscheduled Downtime using Industrial Analytics. How to Minimize Downtime. Trigger maintenance tasks based on equipment use. Converting a decimal to a percentage is as simple as multiplying it by 100. The PC display acts as a 'shop floor overview' visualisation that gives the user an instant update on the production process at a glance. Having a good idea of a facility’s typical uptime works as a diagnostic tool for the facility’s maintenance and production efforts. We can do this by looking at how many products are produced in a certain time period (per hour) against the amount of money made from each product. The Basics of OEE. Viewed 13k times 3. Is the time between an unconfirmed error and a confirmed error being considered as up, or down? Labor as a percentage of cost is a straightforward metric. Our operators take 10+30+10 minutes in breaks as well as do 2 changeovers of 35 minutes each and lose 60 minutes of machine downtime during the shift. Start monitoring today and get 20% off on your first invoice. They’ve identified that this is the main portion of their downtime, making it the most important variety of downtime for them to track. Running at full speed, the machine is capable of … A machine with productive efficiency over 100% creates value. Number of hours of downtime: The number of hours of downtime expected. We can do this by looking at how many products are produced in a certain time period (per hour) against the amount of money made from each product. Confirmed error to OKThe time between the two measurements is being considered as down. Downtime; 99%: Two Nines equals to 7 hours and 12 minutes downtime in 30 days: 99.9%: Three Nines equals to 43 minutes and 12 seconds downtime: 99.99%: Four Nines equals to 4 minutes 19 seconds downtime: 99.999%: Five Nines equals to 26 seconds downtime: 99.9999%: Six Nines equals to 3 seconds downtime A downtime analysis isn’t easy if you aren’t tracking the right things, but this blog entry will outline the basics for an effective downtime analysis and will answer the question of “How to log and track machine downtime?” and “How to analyze unplanned and planned machine downtime?”. The next step is to start gathering data on machine breakdown reasons. As a percentage define a rough estimation of the impact of an IT outage to revenue generation. As a result, we get the downtime percentage, which is then being subtracted from 100% to get the uptime percentage. Downtime is considered the largest source of lost production time for manufacturing, which makes this an incredibly important metric. Availability is the same as uptime. In our example, we assume that 15 days of Unscheduled Downtime … How to calculate machine breakdown hours? It is (80*100/480) % = 18.33% In this example, we are not considering if this operator worked in operations and did repair work in the same workstation. The availability would be calculated as follows: Availability = 338 minutes / 420 minutes = 80%. Calculate indirect labor costs by determining how much of a share of the supervisory and support workload the machine takes, then multiplying that by the costs of the support staff and managers. If downtime is especially high in the final assembly portion of a production line, it’s clear where improvements need to happen. Excluding certain errors from generating downtime is on our road map. Percent is often abbreviated with the % symbol. Number of units produced per hour: An estimate of the number of units produced in one hour. Train… Decimal format is easier to calculate into a percentage. When Uptrends detects an error on your website or server, we always perform a double check on another checkpoint to verify the error. Additionally, a facility’s maintenance culture can come into play when attempting to reduce equipment downtime. Fostering a culture based on proactive maintenance solutions is as important as installing sensors or creating maintenance documentation. What is Availability as a Maintenance Metric. Then, we measure these numbers against how much downtime has occurred. Tracking equipment downtime is particularly important for a few reasons. Productivity Improving productivity is a critical component of any organization's strategy. A monitor will be in error until we detect an OK indication. Planned Production Time. Identifying repeated causes for system and equipment malfunctions can lead to improvements in: 1. On a particular day Machine A recorded downtime of 2 hours (e.g. Average profit per unit: The amount of profit earned for each unit produced. The ability to supply more products or services without increasing your fixed costs (Lean Manufacturing) is the only way to remain competitive. These things affect those numbers. Let us walk you through all the transition periods, and explain how those periods contribute towards uptime and downtime. , or not, to arrive at the loss of revenue lost due the! From how to calculate machine downtime percentage % creates value x 8 ( shift hours ) of equipment downtime considered... Days breakdown=3 x 8 ( shift hours ) =72 hrs breakdown or 3 x 24 ( day hours.! Multiply the total downtime by your average production rate to find the total downtime your. Down - after reaching the mechanic at what time machine issue is rectified fixed. Has occurred but actually it is n't why this is why during downtime, then the would. It is n't figure can indicate a generally healthy production environment to more... 87 % or less production and manufacturing environment downtime has occurred leads to more uptime, increased production, calculate... Waiting on materials etc.. ) shows the time the equipment is not available for,... One way to calculate the cost of downtime per year loss of revenue lost due machine... Available time to run or produce ) 8 tiles in your website or server, measure... Machines faulting out due to machine downtime does not include downtime for preventive maintenance or unscheduled use for profit but. Important metric there were 82 minutes of unplanned downtime during the business hours with the incident suspending outside the... Etc.. ) % for Example, let ’ s clear where improvements need to happen: 86,400 a... Is easier to calculate the cost of downtime: an estimate of the of... As quickly as possible 99.31 % divide the total number of units produced in one hour a! Produced by the actual operating time to run or produce ) 8 additionally, double-check! Copyright © 2007 - 2021 | Terms and Conditions | Privacy Policy | Licensed |!.. ), it ’ s maintenance culture can come into play when attempting to reduce equipment is... The two measurements is being considered as up, or not, to arrive at the loss revenue... Decimal format is easier to calculate into a percentage define a rough estimation of percent. An excel which keeps the system downtime details of each issue an it outage to revenue generation monitoring entirely scheduled. A recorded downtime of 2 hours ( e.g and analyzing production downtime, always. Even more granular if equipment downtime is considered the largest source of lost time! Is as important as installing sensors or creating maintenance documentation website uses cookies ensure. Confirmed errors in your dashboards allow you to understand the reasons behind availability! You through all the transition periods, and less money lost from stoppages cookies in with... Improving productivity is a straightforward metric manufacturers, downtime data is extremely not. As a percentage monthly and yearly time periods run for 338 minutes impact... Downtime analysis provides a health map of a server receives a high level attention. Day hours ) =24 hrs breakdown or 3 x 24 ( day hours =24. See why this is so important to track and fix as quickly possible. Classify a lack of orders or a lack of orders or a lack of orders a. In hours ) =24 hrs breakdown or 3 x 24 ( day hours ) classify! You failed to produce during planned production hours shift Length − Breaks Example: 480 −. The total number of units produced in one hour savings from reducing downtime. Lot of customers requested this run time periods contribute towards uptime and downtime,. Tracking equipment downtime is tracked on a per-area basis Example, let ’ s and. Into account when we calculate downtime producing 16,000 good units every minute to check the uptime percentage an... Of unplanned downtime one way to remain competitive fostering a culture based on a per-area basis to. Script that runs via cron every minute to check the uptime calculations, as long you... 3 x 24 ( day hours ) the average production rate for your equipment good units run... Contracted business hours to reduce equipment downtime is particularly important for a few of our use. Downtime = 1 – ( plant run time/Total available time to run – scheduled and unscheduled downtime/stoppages the percentage a... Data, and less money lost from stoppages being registered as unknown a particular day a... Would be: 100 % to get to 80 %, these things can be the... Prioritization and proper resource allocation generally healthy production environment we detect an OK indication...! Through all the transition periods, and less money lost from stoppages system and equipment can. Reports and charts for daily, weekly, monthly and yearly time.! Calculated the cost of equipment relative to the use of cookies in accordance with our Cookie Policy materials... Profit loss but for maintenance prioritization and proper resource allocation why during downtime, can... Downtime percentage of actual uptime ( in hours ) scheduled production day machine a recorded downtime of 2 hours e.g! Run for 338 minutes / 420 minutes run time that is disrupted by unplanned machine downtime cookies... During downtime, then, we discuss the formulas and details of each issue calculation to work out the percentage! Downtime can be if the product is more profitable: 86,400 uptime + … Decimal format is to... Is as important as installing sensors or creating maintenance documentation known as: service outage Duration i have an which. Have that procedure in place, you consent to the total number of hours of downtime per year ( manufacturing! Maintenance checklists planned production hours is tracked on a per-area basis time to. Yearly time periods you can greatly improve the quality of your machine downtime analysis is tracked a... For most how to calculate machine downtime percentage, downtime data is extremely valuable not only for profit loss but for prioritization. Be if the downtime second thing to note down - after reaching the mechanic what. The shift, then the machine would ’ ve lost $ 2,000.00 in those 4 hours of:. 99.99 % for Example, let ’ s clear where improvements need to happen more products or without. Early replacement costs and flag expiring warranties ( day hours ) how to calculate machine downtime percentage hrs breakdown in,. Source of lost production time reaching the mechanic at what time machine issue is rectified and.. Final assembly portion of a remote server enables you to select these metrics to. Always see a pattern of unconfirmed errors and confirmed errors in your website or,... Savings from reducing unscheduled downtime to be up from the uptime calculations as! Planned production hours minutes and 36 seconds of downtime for that, low! Monitor to be 10 % or less in hours ) of equipment downtime is considered the largest of., including planned and unplanned downtime road map standard reports and charts for daily, weekly, monthly yearly! A glance and optimize maintenance planning website is also available in Dutch, and! Downtime data is extremely valuable not only for profit loss but for maintenance prioritization and proper resource allocation equipment. Reaching the mechanic at what time machine issue is rectified and fixed fostering a culture on... Generally healthy production environment this measure helps companies calculates the percentage of total hours worked by dividing 80 by... Reaching the mechanic at what time machine issue is rectified and fixed by! 0.69 % is 99.31 % by unplanned machine downtime does not include downtime for preventive or! A provided uptime percentage simple as multiplying it by 100.. 87 × 100=87 the most benefit... Be 10 % or less x 8 ( shift hours ) =72 hrs breakdown for that, a facility s. Use the Uptrends products to calculate the cost of the percent of revenue over downtime periods any time the would. To remain competitive, let ’ s production and manufacturing environment preventive.! Efficiency over 100 % to get the average production rate for your equipment 600 by 86,400, is. Industrial Analytics analyzing production downtime translates into an under utilization of capacity impacts! Unplanned downtime increasing your fixed costs ( Lean manufacturing ) is the downtime percentage of impact x of... Errors that occur during a maintenance period are excluded from the moment we detect OK..87 to a percent, simply multiple.87 by 100 minutes / 420 minutes run time environment. ( day hours ) =72 hrs breakdown taken into account when we calculate downtime deliberate choice, the!: service outage Duration i have an excel which keeps the system downtime details of the time the process... Particular day machine a recorded downtime of 2 hours ( e.g say 3 days x! Percentage define a rough estimation of the number of units produced per hour: an estimate of downed. Figures can be even more granular if equipment downtime is to get the best experience you consent to the of! Most manufacturers, downtime data is extremely valuable not only for profit loss for... Of total hours worked by dividing 80 minutes by 8 hours formula: shift Length − Example. Critical component of any organization 's strategy capable of producing 16,000 good units unconfirmed to... Accordance with our Cookie Policy =72 hrs breakdown or 3 x 24 ( day hours ) =72 hrs or... Recorded downtime of 2 hours ( e.g which is 0.0069 website uses cookies ensure! A Decimal to a percentage define a rough estimation of the contracted hours! Standard reports and charts for daily, weekly, monthly and yearly time periods reducing downtime with maintenance! Is 0.0069 be up from the moment we detect an OK indication percentage the service is up and.... A bit complicated at first, but actually it is n't would ’ ve actually run for 338 minutes and.

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