22. Machine monitoring – downtime at shift change

Machine monitoring system – how it shows up downtime at the start and end of shifts
One of the results of poor work ethics on the shop floor is downtimes at the start and end of the shift. Caused by the operator arriving late at the machine at the start of the shift, or leaving the machine early at the end of the shift.

Here is an example, a real report from an actual shop floor. This screen shot from LEANworx Cloud machine monitoring system shows the downtimes at the start and end of the 1st and 2nd shifts, over a week.
This is of a machine that runs 2 shifts, with supervisors present only during the general shift from 9 AM to 5 PM.

The number in the ‘Downtime at end’ column in row 2 indicates that the operator left 47 minutes and 15 seconds earlier than the shift end (which is 10 PM). On day 2 he left 41 minutes and 53 dseconds earlier than he should have. The numbers highligted by arrows show the bigger downtimes. You’ll notice that in the 1st shift the operator started the machine quite late on a couple of days, and in the second shift he consistently stopped the machine early almost every day.
The total at the bottom shows that starting late and stopping early accounted for almost 5.5 hours over the week.
The machine in this report costs Rs. 900 per day, meaning the cost of this downtime was Rs. 5000. You can easliy fix this with a machine monitoring system. Just display everybody’s data to everbody else, on a common large screen monitor. There’s no need to talk to any operators, point out the issue, or do anything else.
By the way, LEANworx Cloud costs Rs. 75 per day per machine, or Rs. 500 per week. Versus Rs. 5000 lost due to downtime for just this one reason. That’s the cost-benefit of a machine monitoring system !
Want to know more about how LEANworx can help you implement Industry 4.0 and smart manufacturing rapidly and economically ? Click here.

Etc
Jalebi and Imarti (alias Jangiri) – what’s the difference ?
There is a cousin of the Jalebi, called Imarti in the North, and Jangiri in the South. It looks similar, but actually has a bunch of differences. The jalebi is made of maida, while the jangiri is made of Urad dal. The jalebi is flat, while the Jangiri is about twice as tall. The jalebi is crunchy, while the jangri is soft. The jalebi originated in Persia, while the jangiri originated in North India. The Jalebi is fermented with yoghurt overnight, while the jangri requires no fermentation. Imarat means ‘building’ in Urdu. The imarti is built in layers, and I wonder if it got its name because of this ?

The Jangiri is thought to have got its name from the Mughal emperor Jahangir (1569 – 1627), because it was his favourite sweet.
Jahangir’s father was Akbar, and his son was Shah Jahan, who built the Taj Mahal. Jahangir is also the Salim of the famous love story Salim-Anarkali (on which the movie Mughal-e-Azam was based). As a prince his name was Salim, and Anarkali was a court dancer that he fell in love with. His Dad of course forbade the relationship because Anarkali was not of royal blood and a courtesan to boot. This actually led to a war between the two, which the son lost, etc., and Salim finally had to quit Anarkali. Being a ‘never give up’ guy, he went on to marry 20 women after he became king. If you think 20 wives is a bit much, his Dad Akbar had 35 !

Jahangir

Salim and Anarkali
Salim became Jahangir when he ascended the throne. In Persian and Urdu, Jahangir means ‘conqueror of the world’. Jahan means World, and ‘gir’ is the the root of the Persian verb gereftan, which means to seize, or grab. I guess it is also the root of the Urdu words giraftaar (to seize, or imprison) and girebaan (the neck of a shirt).
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