1. Iwoscan
  2. Applications
  3. Manufacturing Downtime
MANUFACTURING DOWNTIME RECORDING AND CAUSE ANALYSIS

Record manufacturing downtime where it occurs

Iwoscan records Running, Setup, Downtime and Maintenance states at the workstation. When a stoppage exceeds a defined threshold, the operator selects a downtime cause and the system links the event to the workstation, job, product and operator. Managers see not only how long production was stopped, but also which causes should be addressed first.

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Manufacturing downtime recording with Iwoscan

How Iwoscan helps manage manufacturing downtime

Downtime management requires three reliable data points: when the process stopped, how long it remained stopped and why it stopped. Iwoscan collects this information during production.


Manufacturing downtime duration recording

Downtime duration is recorded at the workstation

The recorder tracks the workstation state and calculates the duration of each stoppage. There is no need to reconstruct the exact start and end time at the end of a shift.

Downtime cause selection

The operator selects a specific cause

When a stoppage exceeds the defined threshold, the operator selects a cause from a configured list, such as equipment failure, material shortage, setup, waiting or quality inspection.

Manufacturing context for a downtime event

Downtime is linked to its production context

Each record includes the workstation, operator, job, product, start time and end time. The same cause can therefore be compared across shifts, products and equipment.

Real-time downtime report

Current production status is visible in real time

Managers can see which workstations are running, in setup, stopped or under maintenance. A long stoppage becomes visible without waiting for a shift or weekly report.

Recurring downtime cause analysis

Causes are ranked by production time lost

Reports show both the number of events and their total duration. This separates a frequent short interruption from a less frequent problem that consumes far more production time.

Downtime data integration

Data is passed to other systems

Downtime and cause data can be passed to an ERP, MRP or another production management system. Data can also be exported in CSV, JSON or binary format.

From a stoppage to a measurable action

Iwoscan does not eliminate downtime by itself. It provides the duration, cause and production context required to choose a justified action and verify the result.

  • 1

    The workstation stoppage is recorded

    The system records the state change and measures how long the workstation is not producing. Short interruptions can be separated from downtime using a defined threshold.

  • 2

    The operator is asked for a downtime cause

    When the stoppage exceeds the defined duration, the operator selects the appropriate cause on the terminal. The list is configured for the actual production process.

  • 3

    Downtime is linked to the active job

    The record includes the product, job, operator, workstation and duration. Setup, adjustment, failure, maintenance and waiting can be recorded as separate states when required.

  • 4

    Problems are ranked by their impact

    Managers compare downtime duration and frequency by cause, workstation, shift or product. This identifies the problem that consumes the most production time.

  • 5

    The result of the change is verified

    After changes to maintenance, process, supply or work organisation, periods are compared. This shows whether downtime caused by the targeted problem actually decreased.

Is Iwoscan suitable for your downtime management process?

Leave your name, email address and phone number. We will contact you to discuss how manufacturing downtime is currently recorded, which causes need to be separated and whether integration with your existing system is required.

What the production team gets

Downtime data becomes useful when it can be linked to the actual production process and compared before and after a change.

Manufacturing downtime duration

Accurate start time and duration

Downtime is calculated from the workstation state rather than estimated and entered at the end of a shift.

Downtime cause classification

Consistent cause classification

Operators select from an agreed list, preventing the same problem from appearing under several different names in reports.

Downtime priority analysis

Priorities based on lost production time

Causes are compared by total duration and frequency, so the problem with the greatest impact can be addressed first.

Downtime context data

Clear production context

Downtime is linked to the workstation, job, product and operator, allowing the data to be analysed from the required perspective.

Local downtime data storage

Recording during network interruptions

The recorder stores data at the workstation first, so event recording continues during temporary network interruptions.

ERP and MRP downtime integration

Integration with existing systems

Downtime data can supplement the ERP, MRP, maintenance or other production management process already used by the company.

Show us one production workstation

Briefly describe the process, equipment and data that is currently missing.

We will explain what can be recorded, which Iwoscan set is suitable and how the data can reach your systems.

Discuss your process

Key questions before implementing downtime tracking

Does Iwoscan detect manufacturing downtime automatically?

The system can record the workstation state and stoppage duration automatically when it receives a cycle, job or other process signal. It does not guess the cause: the cause is selected by the operator or supplied by a connected system.

How does an operator enter a downtime cause?

When a stoppage exceeds the defined threshold, the terminal displays a cause list configured for that workstation. The operator selects one value and the system automatically adds the time, workstation, job, product and operator.

Can planned and unplanned downtime be separated?

Yes. Setup, breaks, adjustment, planned maintenance, equipment failure, material waiting and other states can be recorded separately. The classification is configured for the company's production process.

Do we need to replace our existing ERP, MRP or maintenance system?

Not necessarily. Iwoscan can collect downtime data at workstations and pass it to the system already in use. The integration scope is defined after reviewing the existing software and its data interfaces.

What is needed to start an implementation?

The first step is to choose one workstation or process, define the duration after which a stoppage counts as downtime, and create a meaningful cause list. The data collection method, reports and required integration can then be selected.

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