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.
If you let us know the scenario and signals, we'll set this up for you.
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.
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