Machine downtime analysis – night shift downtime

Machine downtime analysis – detect operator sleeping at night

Here is an example of machine downtime analysis for the night shift, and how it enables you fix downtimes caused by a work ethics issue – operators sleeping in the night shift.

Machine downtime analysis for night shift – operator sleeping

This is a real report from an actual shop floor, showing the operator bunking work in the second half of the night shift. Basically sleeping between 2 AM and 6 AM. This is from a shop that runs 3 shifts, with only half the machines running in the 3rd shift, when there are no supervisors present. This screen shot from the LEANworx Cloud machine monitoring system shows the production every hour for 3 shifts, over 5 days. Each row is a shift, and columns show the production in each hour of the 8-hour shift. The last column shows the total production in the shift.

You will notice that the production in the 1st and 2nd shifts is typically around 45, while in the 3rd shift it is less than 30 (the numbers highlighted with arrows). The 3rd shift production is almost half that in the other shifts. Notice the numbers in the red ovals ? These are the hourly production in the second half of the 3rd shift, between 2 AM and 6 AM. The production is almost zero in this period, every day. This can mean only one thing. The operator is sleeping for half the night shift ! The machine in this report costs Rs. 900 per day, meaning this downtime is costing Rs. 20,000 every week.

You can easily fix this with a machine monitoring system. Just display everybody’s data to everbody else, on a common large screen monitor, called the Andon board in TPM. 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. 20,000 lost due to downtime for just this one reason. That’s the cost-benefit of a machine monitoring system.


Poha and Jalebi breakfast in Indore

Two things I like about Indore. One, it is clean, way cleaner than my home city of Bangalore. Two, the breakfast of Poha and Jalebi that is the standard there.

There are a whole lot of small eateries around the city that serve these. Most of them are standing-only places, with no tables. You just stand on the footpath or wherever the front of the shop faces, and eat right there. The poha and jalebi are both freshly made, cooked right there in front of you. The small mountain of poha has steam rising from it, like a little edible volcano.

The jalebi shop on the right, and a Bhang shop on the left
Jalebis getting fried in the pan on the right, and soaking in sugar syrup on the left

The jalebis are fried in a large pan right there, and chucked into a pan with sugar syrup before being served to you. Both taste great, one healthy and the other unhealthy as hell. I find jalebis terribly addictive, and tend to eat a bunch of them at one shot. In this shop I ate 8. According to Wikipedia, the Jalebi originated in Persia, present day Iran. The name is derived from the Arabic Zalabia and the Persian Zolbiya. It is particularly popular in India and Iran. The Jalebi also exists in a number of other countries – Sri lanka, Nepal, Pakistan, Somalia, Egypt, Ethiopia, Tunisia, Azerbaizan and the Levant (Cyprus, Egypt, Iraq, Israel, Jordan, Lebanon, Palestine, Syria, and Turkey). That’s a lot of countries !

About his blog from LEANworx: Plug-and-play Industry 4.0 system for MSMEs.

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