Solution

Machine Downtime Tracking and Root Cause Analysis

We build downtime tracking that catches every stop from machine signals, records the reason at the machine and ranks losses so teams fix the right things first.

Let's talk about your project → What we deliver

Our clients

Siemens
Anadolu Isuzu
BSH
Tofaş
Toyotetsu
Martur
Turkcell
Vodafone
Doğadan
Pakmaya
Bross
Abdi İbrahim
Nobel İlaç
Plastimak
Dalgıç Kalıp
Barbaros Motor
Magneti Marelli
Rözmaş
Sanel

Machine downtime tracking records when a machine stopped, for how long and why. Paper downtime logs capture the long breakdowns but lose the short setup stops, material waits and micro-stops, which often add up to a large share of total loss.

VOLSOFT detects the start and end of each stop from PLC or CNC signals and asks the operator for the reason on a terminal at the machine. We design the reason-code tree with your team so it stays simple enough to be used on every shift. Stops are split into planned and unplanned and feed directly into the availability component of OEE.

At Bross, a machine data collection and reporting system was used to analyze production gaps and delays, and the client reported a 15% increase in efficiency in its Clutch review. Downtime tracking, like all our work, runs on Proxus.

What we deliver

Downtime Tracking

Automatic stop detection

Stop start and end come from machine signals; stops below a defined duration count as micro-stops, longer ones require a reason.
Reason-code tree

Categories such as mechanical failure, electrical failure, adjustment, tool or mold change, waiting for material, no operator and planned maintenance, with sub-reasons fitted to your floor.
Planned vs unplanned

Breaks, planned maintenance and no-order time are kept separate so availability and OEE are calculated correctly.
Pareto and trends

Downtime is ranked by machine, line, shift and reason, and the effect of each improvement shows up in the trend.
MTBF, MTTR and maintenance calls

MTBF and MTTR are calculated from failure stops, and when operators call maintenance from the terminal, response time is measured too.

How a project runs

From discovery to live, step by step

01
Downtime definitions

With production and maintenance we agree which signal defines a stop, the micro-stop threshold and planned downtime categories.
02
Reason codes

Existing downtime logs are reviewed and a lean reason-code tree that operators will actually use is designed.
03
Connectivity and terminals

Machines are connected, operator terminals go live and reason entries are validated on the floor over several shifts.
04
Reports and improvement loop

Pareto, MTBF/MTTR and shift reports are delivered, ready for regular loss review meetings.

Built on Proxus

Stop detection runs as Proxus rules on machine signals; downtime events are stored in the historian with their reasons and feed directly into OEE.

Proxus is the industrial data platform built by the VOLSOFT team.

OEE and downtime with Proxus ↗

Frequently asked questions

Common questions

How do you track machine downtime automatically?

Downtime is tracked by taking stop start and end times from PLC or CNC signals and having the operator select the reason on a terminal at the machine. Duration comes from the machine, the reason from the person, which removes estimated times from paper logs.

How should downtime reason codes be structured?

Split stops into planned and unplanned first, then into main categories such as breakdown, adjustment, material, tool or mold change, operator and quality, each with a few sub-reasons. Keep the list short; long lists lead to wrong picks on the floor.

What are micro-stops?

Micro-stops are stops too short to notice individually but frequent enough to matter, such as jams, sensor trips or small adjustments. They rarely appear in manual logs and surface once data is collected automatically. In OEE they are usually treated as a performance loss.

What are MTBF and MTTR?

MTBF, mean time between failures, is total run time divided by the number of failures. MTTR, mean time to repair, is total repair time divided by the number of failures. Both are only reliable when failures are captured automatically with their reasons.

How does downtime tracking relate to OEE?

Unplanned downtime reduces availability, and micro-stops reduce performance, two of the three OEE components. Downtime tracking with reason codes explains why OEE moves, which the OEE number alone cannot do.