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Machine Downtime Data Collection

Six Sigma – iSixSigma Forums Old Forums General Machine Downtime Data Collection

This topic contains 11 replies, has 8 voices, and was last updated by  VTME2003 Hokies 12 years, 11 months ago.

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  • #43858

    danny
    Participant

    Can anyone help??
    I work within a window manufacturing company that uses manual data collection for the machine downtime. The problem is that their is always too much information. I have tried using codes for different aspects of downtime but  I am still having problems capturing the right information.
    Can anyone help?? Does anyone have a tried & tested method that works??

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    #139699

    Ovidiu Contras
    Participant

    Danny,
    the Affinity Diagram can help you group the data based on categories. You can choose these categories yourself, organize the data accordingly, then run a Pareto Chart.
    Hope this helps… 

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    #139702

    sixsigmadeewana
    Member

    How many codes fo you have? Also as per the previous poster’s idea, can you try and combine the codes. From personal experience, do NOT use the code OTHERS or MISCELLANEOUS.
    Try conducting time studies.

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    #139706

    danny
    Participant

    We are currently using a generic form for 8 different machines. We have 5 catagories to record data under. These are:-

    PM – Planned Preventative Maintenace
    PO – Tool Changes etc.
    MB – Machine Breakdown/Service
    NS – No Supply To Machine
    NO – No Operator/Not In Use
    The forms table is headed as follows:-
    Date / Job Number / Production Stopped / Code / Reason – Discription / Production Started / Total Time / Initial
    As indicated earlier, this is a generic form that has been used for over 8 years. Upon appointment to my current position I initially added the codes to try and categorise the information collected.
    The problem is getting the information into an excel spreadsheet and analysing the information correctly. As you can probably tell, I am new to this!!!

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    #139707

    sixsigmadeewana
    Member

    Dont add codes without understanding the process. See if the operators are filling in the codes correctly. One of the issues I have seen is… operators always used the first code from a list of codes since it was “easier” to use it. Is there such a “bias” in your system? You need to check all this before changing the system.
    Then, I suggest that you should put all this information in excel. Pareto it….and lets say you find that tool changes is major cause…. then you could add more categories to it to do a “deep-dive”… and find out why… post ur email if u have more queries
     

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    #139711

    Brit
    Participant

    Seems like you have the necessary info on your sheet. 
    First, are employees recording the total time?  If so, remove that from the sheet and do it through excel after entering the data via a formula (Production Started – Production Stopped). 
    Second (not a biggie) I would remove the date from each record and have one sheet(s) for a date and pick it daily or by shift.  The date would only need to be recorded once at the top.  If you have an outlier, you can find the date via the job number.
    My experience has shown that the Reason – Discription part is rarely filled out properly, especially with very old forms.  I woulsd follow the advice of previous posts and pareto the codes and then concentrate on your most pressing issues.
    By the way – if you need a code for MB and NS, then you may be expecting to experience these as a company.  These, in  my mind, should be top concerns at the moment (not having the data – just an opinion). You may want to try fixing these issues, then sampling your data instead of continuous data collection bythe operators.
    Just some thoughts

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    #139725

    danny
    Participant

    There isn’t any real bias within the operators. I just wasn’t sure if they were capturing the right information. I am trying to now build an excel workbook that I will be able to enter the information in to then analyse it but I am also having difficulty building the spreadsheet.
    email is danny.pidd@eltherington.co.uk

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    #139909

    Engr. Saad
    Participant

    When i am working in this enviroment, Try to break downtime  into 2 major categories
    Avoidable delay (Not necessary and due to ill plaining)
     Unavoidable delays (Necessary delays) 

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    #139917

    EJMiller
    Participant

    Check out the brief case study on machine downtime at http://www.hertzler.com/php/portfolio/case.study.detail.php?article=19

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    #139923

    danny
    Participant

    I have instructed the operators and created detailed works instructions on the filling out of the downtime forms, so hopefully if I start getting the right information I should be able to process it quicker.
    The problem I am now having is creating a Excel sheet to analyze the information collected form the machines.
     

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    #140091

    Paul Gibbons
    Participant

    Sounds to me the problem you have is your approach to collecting the data.
    Take the operators with you, don’t force them to complete complicated forms that they don’t understand. Explain to them what the problems are and ask for their help to design a data collection sheet. Remember, the simplest format is best.
    Suggest you use OEE as your analysis tool.
    Good luck
    Paul 

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    #140103

    VTME2003 Hokies
    Member

    Try a CMMS system such as SAP/MARCAM/MP2. This will facilitate your need to get key reliability data for your assets.

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