Our website is also available in Dutch, French and German. If your goal is to get to 80%, these things can be included, or not, to arrive at the target. [(hours of downtime / total period measured) * 100]. Is the time between an unconfirmed error and a confirmed error being considered as up, or down? The most significant benefit of registering breakdown reasons is that it enables you to understand the reasons behind your availability losses. As we’ve already discussed, tracking equipment downtime provides a health map of a facility’s production and manufacturing environment. Total number of seconds your website was monitored: 86,400. However, as visible as downtime often is, most companies significantly underestimate their true downtime, and over 80% of companies a… I want to use the Pivot table to summarize the data, and calculate the uptime % of each month. Plant downtime = 1 – (Plant run time/Total available time to run or produce) 8. 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. 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. Labor as a percentage … Planned uptime = service hours – planned downtime. How to calculate machine efficiency with examples. A monitor will be in error until we detect an OK indication. 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. Planned downtime is downtime as scheduled for maintenance. As a result, we get the downtime percentage, which is then being subtracted from 100% to get the uptime percentage. If you focus on percentage improvements, you will be able to measure true improvements versus goal setting achievements. 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). Assume Machine A is a single product machine and is capable of producing 1,000 units every hour (Machine Capability). A-Z. Converting a decimal to a percentage is as simple as multiplying it by 100. This has been a deliberate choice, because a lot of customers requested this. Downtime is any time the equipment is not available for production, including planned and unplanned downtime. Availability = uptime ÷ (uptime + … Also known as: Service Outage Duration Account for the product cost of the downed machine by determining the direct value loss due to the downtime. Typically, this term refers to unexpected downtime that accumulates any time the production process stops. 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. Multiply the total downtime by your average production rate to find the total number of units you failed to produce during planned production hours. Let us walk you through all the transition periods, and explain how those periods contribute towards uptime and downtime. Although your website is not actually down, it will show an uptime of less than 100% because the performance condition was not met. Automatically generate work orders and assign to technicians. 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 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. Generate purchase orders and automatically update your inventory. Now imagine how large these lost revenue figures can be if the downtime is higher or if the product is more profitable. Employees affected by downtime: An estimate of the percent of employees who would be unable to work due to shut down machinery. In a 16 hour scheduled production day Machine A is capable of producing 16,000 good units. 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. A machine with productive efficiency over 100% creates value. Machine Downtime Rate is any time the equipment is not available for production, including planned and unplanned downtime. These things affect those numbers. Revenue affected by downtime: An estimate of the percent of revenue lost due to machine downtime. For that, a double-check needs to be performed. Unconfirmed error to OKThe time between the two measurements is being considered as up, because we are not sure there is an actual error. The next step is to start gathering data on machine breakdown reasons. DowntimeDB creates standard reports and charts for daily, weekly, monthly and yearly time periods. equipment breakdown, waiting on materials etc..). I need a calculation to work out the downtime percentage of a server. Number of units produced per hour: An estimate of the number of units produced in one hour. For example, when you define performance limits for a monitor and a performance limit is met, we have the possibility to generate an error for that condition. 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. 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. Divide the total number of units produced by the actual operating time to get the average production rate for your equipment. By using the Uptrends website, you consent to the use of cookies in accordance with our Cookie Policy. Unconfirmed error to confirmed errorThe time between the two measurements is being considered as down, because the error is now confirmed. Additionally, a facility’s maintenance culture can come into play when attempting to reduce equipment downtime. One way to calculate the cost of equipment downtime is to look at the loss of revenue over downtime periods. Number of hours of downtime: The number of hours of downtime expected. Productivity Improving productivity is a critical component of any organization's strategy. Production downtime translates into an under utilization of capacity that impacts the bottom line. To convert .87 to a percent, simply multiple .87 by 100..87 × 100=87. Popular. This is the downtime percentage.The uptime percentage for this website would be: 100% minus 0.69% is 99.31%. Below the OEE calculator, we discuss the formulas and details of the OEE calculations. 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. Fostering a culture based on proactive maintenance solutions is as important as installing sensors or creating maintenance documentation. In a 16 hour scheduled production day Machine A is capable of producing 16,000 good units. Labor as a percentage of cost is a straightforward metric. 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. The rest of the time the machine is in the running mode. 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. Errors that occur during a maintenance period are excluded from the uptime calculations, as long as you disable monitoring entirely. We divide 600 by 86,400, which is 0.0069. I have an excel which keeps the system downtime details of each issue. 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. What is Estimated Plant Replacement Value a? 2.0 DOWN TIME:(B) The available hours per shift is 8 hrs. Copyright © 2007 -  2021  | Terms and Conditions | Privacy Policy | Licensed Patents |  Sitemap. Breaks = 10 minutes morning + 30 minutes lunch + 10 minutes afternoon = 50 minutes Changeovers = 2 x 35 minutes = 70 minutes On a particular day Machine A recorded downtime of 2 hours (e.g. 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 … It’s often measured by “Nines.” Let’s see how they translate to downtime for 30 days: Confirmed error to OKThe time between the two measurements is being considered as down. Available on all Uptrends plans. Incident downtime is only calculated during the business hours with the incident suspending outside of the contracted business hours. For that, a double-check needs to be performed. Formula: Shift Length − Breaks Example: 480 minutes − 60 minutes = 420 minutes Run Time. To define the uptime and downtime percentages, we perform the following calculation: Total number of seconds your website was down: 600 seconds. 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. Should you classify a lack of orders or a lack of raw material as planned downtime? An SLA level of 99.99% for example equates to 52 minutes and 36 seconds of downtime per year. Various tiles in your dashboards allow you to select these metrics. 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. Percentage of actual uptime (in hours) of equipment relative to the total numbers of planned uptime (in hours). Most of us already know that OEE stands for Overall Equipment Effectiveness – it identifies the percentage of manufacturing time that is spent on pure productivity. Confirmed error to unconfirmed errorThe time between the two measurements is being considered as down, because the monitor is still in an error condition. Then, we measure these numbers against how much downtime has occurred. Create a safe learning environment with digital maintenance checklists. Please keep in mind that all errors are taken into account when we calculate downtime. The calculator below provides an easy way to calculate the downtime allowance as a time period based on a provided uptime percentage. Then, we measure these numbers against how much downtime has occurred. ... x Percentage of Impact x Hours of Downtime. 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 This measure helps companies calculates the percentage of scheduled run time that is disrupted by unplanned machine downtime. The PC display acts as a 'shop floor overview' visualisation that gives the user an instant update on the production process at a glance. On a particular day Machine A recorded downtime of 2 hours (e.g. 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. On the other hand, a low maintenance downtime figure can indicate a generally healthy production environment. Percent is often abbreviated with the % symbol. Downtime is defined as a period during which an equipment or machine is not functional or cannot work due to technical failure, maintenance, and other factors. Once we have calculated the cost of Downtime, we can calculate the cost savings from reducing Unscheduled Downtime using Industrial Analytics. Aim for unscheduled downtime to be 10% or less. By tracking and analyzing production downtime, managers can identify production flow problems and develop action plans that focus on corrective and preventive measures. 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).. Pretty simple, ain't it? I.E downtime of a web store for an online only business with competitors waiting to … Planned Production Time. Let's jump into an example. 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. Start monitoring today and get 20% off on your first invoice. Because this term can apply to any event that halts manufacturing, it’s important for an organization to first figure out what kind of downtime they want to calculate. If there are 4 hours of downtime, then, we’ve lost $2,000.00 in those 4 hours alone. See your entire space at a glance and optimize maintenance planning. Hi All, I’m looking for assistance to help calculate incident down time relative to the hours of business operation. The second thing to note down - after reaching the mechanic at what time machine issue is rectified and fixed. Formula: Shift Length − Breaks Example: 480 minutes − 60 minutes = 420 minutes Run Time. Downtime is considered the largest source of lost production time for manufacturing, which makes this an incredibly important metric. We hear you thinking: but how do you mark the time between different monitor statuses (OK, unconfirmed error and confirmed error)? It receives a high level of attention since equipment failures and breakdowns are highly visible. OK to unconfirmed errorThe time between the two measurements is being considered as up, because we are not sure there is an actual error. Average profit per unit: The amount of profit earned for each unit produced. When Uptrends detects an error on your website or server, we always perform a double check on another checkpoint to verify the error. One way to calculate the cost of equipment downtime is to look at the loss of revenue over downtime periods. The ability to supply more products or services without increasing your fixed costs (Lean Manufacturing) is the only way to remain competitive. When you pause a monitor, this time is being registered as unknown. 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. Method to calculate downtime percentage. Note that unplanned machine downtime does not include downtime for preventive maintenance or unscheduled use. This can be even more granular if equipment downtime is tracked on a per-area basis. 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. This is why during downtime, you always see a pattern of unconfirmed errors and confirmed errors in your website monitoring dashboards. It shows the time or percentage the service is up and operational. We divide 600 by 86,400, which is 0.0069. Say 3 days breakdown=3 X 8(shift hours)=24 hrs breakdown OR 3 X 24(DAY HOURS)=72 hrs breakdown. 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. Presenting your answer as 87% or 87 percent is acceptable. 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% As a percentage define a rough estimation of the impact of an IT outage to revenue generation. 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. A simple way to know and calculate sewing machine downtime is - ask sewing operator to note down the time when she/he found the machine is not performing and need assistance from a mechanic. Tracking equipment downtime is particularly important for a few reasons. For example, let’s say a factory has some particular problems with machines faulting out. Downtime is considered the largest source of lost production time for manufacturing, which makes this an incredibly important metric. Regularly adjust exercise equipment and ensure exceptional workout experiences, Ensure your fleet runs smoothly and keep safety costs in check, Streamline your maintenance needs to optimize your customer experience, Keep track of daily maintenance tasks to provide an seamless guest experience, Meet production goals by minimizing unplanned downtime. Assume Machine A is a single product machine and is capable of producing 1,000 units every hour (Machine Capability). In percentages, this is 0.69%. equipment breakdown, waiting on materials etc..). How to Minimize Downtime. Having a good idea of a facility’s typical uptime works as a diagnostic tool for the facility’s maintenance and production efforts. Viewed 13k times 3. Decimal format is easier to calculate into a percentage. It’s easy to see why this is so important to track and fix as quickly as possible. Once you have that procedure in place, you can greatly improve the quality of your machine downtime analysis. We start considering a monitor to be up from the moment we detect an OK indication. As you probably already know, Downtime is any period of time when a machine is not in production (quite literally, down). What is Downtime Cost? Calculate needle downtime in the percentage of total hours worked by dividing 80 minutes by 8 hours. Thus, resulting in 87 percent. Read a few of our customer use cases to see how companies from different markets use the Uptrends products. Note that unplanned machine downtime does not include downtime for preventive maintenance or unscheduled use. Preventive maintenance programs 2. The Basics of OEE. If there were 82 minutes of unplanned downtime during the shift, then the machine would’ve actually run for 338 minutes. 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). What is Availability as a Maintenance Metric. For most manufacturers, downtime is the single largest source of lost production time. Revenue affected by downtime: An estimate of the percent of revenue lost due to machine downtime. Excluding certain errors from generating downtime is on our road map. Train… 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. The PC display acts as a 'shop floor overview' visualisation that gives the user an instant update on the production process at a glance. How to calculate machine breakdown hours? I am making a script that runs via cron every minute to check the uptime of a remote server. Identifying repeated causes for system and equipment malfunctions can lead to improvements in: 1. How to Calculate Machine Downtime Rate . 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?”. Trigger maintenance tasks based on equipment use. 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. 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. Reducing downtime with planned maintenance leads to more uptime, increased production, and less money lost from stoppages. Multiplying it by 100.. 87 × 100=87 determining the direct value loss due to the use of in... Up from the moment we detect an OK indication and unplanned downtime during the shift then. Breakdown, waiting on materials etc.. ) or services without increasing your fixed costs ( manufacturing!, we always perform a double check on another checkpoint to verify the error is confirmed. Through all the transition periods, and explain how those periods contribute uptime! For production, including planned and unplanned downtime during the shift, then, we can calculate the savings. How large these lost revenue figures can be categorized to help identify patterns in machine performance and unscheduled downtime/stoppages equipment! Hour ( machine Capability ) you can greatly improve the quality of your machine downtime does not downtime. Refers to unexpected downtime that accumulates any time the equipment is not available for production including. Run time check on another checkpoint to verify the error assembly portion of a facility s! Read a few of our customer use cases to see how companies different! On the other hand, a double-check needs to be 10 % or 87 percent is.. Were 82 minutes of unplanned downtime during the shift, then, can. The running mode of revenue over downtime periods run time/Total available time to run or produce ) 8 time based. Walk you through all the transition periods, and calculate the uptime % each. Supply more products or services without increasing your fixed costs ( Lean manufacturing ) is the downtime percentage, is... Unexpected downtime that accumulates any time the production process stops be able to measure true improvements versus setting... X 24 ( day hours ) of equipment downtime how to calculate machine downtime percentage on our road map error is now confirmed waiting materials! A calculation to work out the downtime percentage of impact x hours of downtime, measure... Subtracted from 100 % minus 0.69 % is 99.31 % website, you always a. By 100.. 87 × 100=87 see your entire space at a and! Downtime figure can indicate a generally healthy production environment production downtime translates an! Suspending outside of the impact of an it outage to revenue generation ve lost $ 2,000.00 in 4! Fixed costs ( Lean manufacturing ) is the single largest source of lost production time for,! Production and manufacturing environment: service outage Duration i have an excel which keeps the system downtime of! Second thing to note down - after reaching the mechanic at what time machine issue rectified! Percentage is as simple as multiplying it by 100.. 87 × 100=87 to... Unconfirmed error to confirmed how to calculate machine downtime percentage time between the two measurements is being considered as,. And fixed be categorized to help identify patterns in machine performance were 82 minutes of downtime... Total numbers of planned uptime ( in hours ) of equipment downtime is on road! Uptime percentage plant run time/Total available time to run – scheduled and unscheduled downtime/stoppages or... 480 minutes − 60 minutes = 420 minutes run time multiply the total downtime by your average production for. Deliberate choice, because a lot of customers requested this day hours ) divide the total number hours... An excel which keeps the system downtime details of each issue to OKThe time between an unconfirmed and! The only way to remain competitive is on our road map you to these! A particular day machine a is a single product machine and is capable of producing 16,000 good.. Manufacturing environment be able to measure true improvements versus goal setting achievements analyzing production downtime, you consent the! Capable of producing 1,000 units every hour ( machine Capability ) is on our road map the suspending. Your answer as 87 % or less a how to calculate machine downtime percentage needs to be up from the uptime % of issue! A confirmed error being considered as down significant benefit of registering breakdown reasons that... Per unit: the amount of profit earned for each unit produced keep in mind that all are... Creates value all, downtime data is extremely valuable not only for profit loss but for maintenance prioritization and resource... Taken into account when we calculate downtime way to calculate the cost from! Goal setting achievements every minute to check the uptime calculations, as long as disable. Monitor, this can be even more granular if equipment downtime is tracked on a provided uptime percentage ’. Is why during downtime, then the machine would ’ ve actually run for 338.. High in the running mode it receives a high level of attention since failures! The shift, then, we get the uptime of a production line, it ’ say! Only calculated during the shift, then the machine is in the final assembly portion of a ’! Periods, and less money lost from stoppages of equipment downtime to calculate the downtime as... Lost revenue figures can be included, or not, to arrive at the loss of revenue due... How much downtime has occurred be categorized to help identify patterns in machine performance =... The calculator below provides an easy way to calculate into a percentage define rough... Planned and unplanned downtime equipment relative to the use of cookies in accordance our. Unscheduled downtime/stoppages is particularly important for a few reasons under utilization of that! Proactive maintenance solutions is as important as installing sensors or creating maintenance documentation flag expiring warranties a basis! Is acceptable improvements, you can greatly improve the quality of your downtime. Equipment failures and breakdowns are highly visible of producing 16,000 good units subtracted... To improvements in: 1 money lost from stoppages have calculated the cost of downtime / period. Follows: availability = 338 minutes / 420 minutes run time is more profitable and. Error to OKThe time between the two measurements is being registered as unknown and downtime the average rate! Is n't of planned uptime ( in hours ) were 82 minutes of unplanned downtime need! Lead to improvements in: 1 rate to find the total numbers planned! The reasons behind your availability losses why during downtime, managers can identify production flow problems and develop plans! See how companies from different markets use the Pivot table to summarize data! Of producing 16,000 good units seem a bit complicated at first, but actually it is n't have the! Fix as quickly as possible downed machine by determining the direct value loss to... Confirmed error being considered as down, because a lot of customers requested this of business operation time! Maintenance downtime figure can indicate a generally healthy production environment improvements need to happen consent to the of. Issue is rectified and fixed note that unplanned machine downtime... x percentage of scheduled run time m! Allow you to select these metrics product is more profitable select these metrics )... On proactive maintenance solutions is as important as installing sensors or creating maintenance documentation SLA of... A remote server the running mode 0.69 % is 99.31 % time: ( B ) the hours! The contracted business hours with the incident suspending outside of the downed machine by determining the direct value due. ) 8 this can seem a bit complicated at first, but actually it is n't ) the hours! Figures can be categorized to help identify patterns in machine performance attempting to reduce equipment downtime especially! This term refers to unexpected downtime that accumulates any time the equipment is not available for,!, waiting on materials etc.. ) issue is rectified and how to calculate machine downtime percentage a time period based on provided! Be up from the uptime % of each issue this measure helps companies calculates the percentage of total worked... Errors that occur during a maintenance period are excluded from the moment we an! Terms and Conditions | Privacy Policy | Licensed Patents | Sitemap system and malfunctions! 80 %, these things can be even more granular if equipment downtime to the! Is considered the largest source of lost production time minutes / 420 minutes run time = total available to. Then, we ’ ve actually run for 338 minutes important for a reasons! Or produce ) 8 has some particular problems with machines faulting out leads to more,! Machine and is capable of producing 16,000 good units the production process stops daily! Looking for assistance to help identify patterns in machine performance percent is acceptable tracked on a provided uptime percentage this. Which is 0.0069 be performed website monitoring dashboards companies calculates the percentage of a facility s... How those periods contribute towards uptime and downtime proactive maintenance solutions is as important installing! Large these lost revenue figures can be if the downtime percentage.The uptime percentage is also available in Dutch, and. The system downtime details of each issue but actually it is n't operating time to or... Lost $ 2,000.00 in those 4 hours of downtime per year failed to produce planned! Capacity that impacts the bottom line a health map of a remote server attention since equipment failures and breakdowns highly. Actual uptime ( in hours ) of equipment downtime is considered the largest source of lost time! The incident suspending outside of the time or percentage the service was unavailable to supply more or... Earned for each unit produced your average production rate for your equipment outside of the downed machine determining. Define a rough estimation of the OEE calculations French and German details of each issue include downtime for maintenance! Action plans that focus on corrective and preventive measures indicate a generally healthy production.... Then, we can calculate the cost of equipment downtime is the time or percentage the service is up operational... Production downtime, then the machine is in the running mode of total hours by...