Automatic Downtime Categorization

How does it work?

We use simple If That Then This (IFTTT) logic scenarios to automatically set the downtime category for the machine. We combine one or more triggers to create an action. We use time, data items, machine signals and IO inputs for our triggers.

How do i enable Auto Downtime?

Simply start adding rules to the auto downtime lab and click save.

What is a Downtime Category?

In simple terms, a downtime category is a way of labeling why a machine has stopped working during production. When a machine goes idle or isn't running, we can assign it a "downtime category" to understand the reason behind the pause. These categories help us see if the stoppage is due to a specific issue, like a machine fault, a production bottleneck, or another cause that may affect productivity.

This information is useful for improving performance, as it highlights areas where production might be slowed down. Downtime can be categorized manually by an operator or supervisor, who observes and records the reason, or it can be done automatically with pre-set logic that detects certain conditions. This lets companies track downtime accurately, find patterns, and make adjustments to improve overall efficiency.

What do you need to know to create a scenario?

You will often need to guide us on the scenarios of what different downtime events look like and also where we can source the signals from. 

For example, in the image above we have MACHINE IDLE & DOOR OPEN & TOOL RELEASE BUTTON PRESS = TOOL CHANGE. In this scenario we need to know from you the PLC address of the DOOR OPEN and TOOL RELEASE BUTTON. We already know the machine status.

How do you find the signals and addresses?

You can find the necessary information within the machine wiring diagram or PLC ladder diagram. The PLC diagram generally provides the most detailed insights and is typically accessed on the control interface by a maintenance or service engineer. Wiring diagrams are usually located in the electrical cabinet, saved on a USB, displayed on the HMI, or available with the maintenance team. In the wiring diagram, input signals are identified by X addresses, while outputs are marked as Y.

In this image we can see the door interlock signal for the door is X9.1.

If you let MachineMetrics know this signal information, we can map it for you.

Auto Downtime Lab

In this Lab you can configure the trigger for each auto downtime.

Mode:

Alarm: This is the alarm number or code

Alarm-message: This is the alarm text, so you can say if the alarm text contains a specific string

State: The state of a data item in the diagnostics page (you will need the data item name, not the display text)

Active Seconds to Ignore

If the machine starts running for a short period of time and stops again, how many seconds do we need to run before we assume this downtime no longer applies.

Strict Mode

Off: When a trigger is activated, the entire duration of the downtime will be categorized under the trigger event.

Strict Start: Downtime will begin as soon as the trigger is activated.

Strict End: Downtime will conclude when the trigger is deactivated.

Strict: Downtime will start and end in exact alignment with the trigger, mirroring its activation and deactivation. This is a great option for events like breaks.

Sample Adapter Scripts

Machine is online / offline

version: 2

declare-keys:
  - avail
variables:
  is-online:
    - source: avail == "AVAILABLE"
    - when-unavailable: false
    - expression: this ? (1):(0)

data-items:
  - is-online

Breaktime 10:30 - 10:45am

Learn more about using CRON

version: 2

generators:
  flag-morning-break:
    type: cron
    cron: "0 30 10 * * 1-5" # 10:30 AM, Monday-Friday
    duration: 15m # 15 minutes (10:30-10:45 AM)
    timezone: America/New_York

variables:
# ADT break flag - outputs 1 during break, 0 otherwise
  adt-break:
    - expression: flag-morning-break == true ? 1:0

data-items:
  - adt-break

Non Scripting ADT

In the image above, if the data item for single block is 1, then we automate the downtime to be Operator | Single Block.

If the block (line of code) contains M0, then we automate the downtime to be Process | M0 Active.

These are valuable to understnad if operators are effecting machine performance.