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Automatic Downtime Tracking

Rutherford Wilson
  • Updated

Automatic Downtime Tracking (ADT) identifies, records, and categorizes downtime events without requiring operator input. MachineMetrics continuously monitors machine state signals to detect when a machine stops producing parts, then automatically applies downtime categories using rule-based logic.

ADT helps teams understand why machines go idle, uncover process bottlenecks, reduce manual reporting, and drive more accurate OEE and performance analytics.

Feature Availability

Requirement Details
Module Core Platform
Optional Add-Ons None (ADT is included as part of downtime tracking; rule-based classification is native)
Real-Time Requirements Machine connectivity with status signals (e.g., in-cycle, idle, powered)
Access Level Viewable by Operators, Supervisors, Editable by Executive, Manager, and IT Admin

How It Works

MachineMetrics continuously monitors machine state changes:

  • When a machine leaves a productive state (in-cycle), ADT detects the transition into downtime.

  • When the machine resumes production, the downtime event ends.

  • ADT stores the start and end timestamps for real-time status in ShopPulse and long-term analysis in reports.

Once downtime is detected, ADT uses If-This-Then-That (IFTTT) logic to automatically assign downtime categories.
Rules can reference:

  • Machine states

  • Alarms or alarm text

  • IO signals (door open, tool release button, etc.)

  • Time-based triggers

  • Setup / Setup Activity Types 

How to Use It

Operator Workflow (ShopPulse)

  • Operators see downtime states automatically when the machine transitions to idle.

  • If manual downtime entry is enabled, operators may choose a reason.

  • When the machine resumes cycle, ADT automatically closes the downtime event.

Supervisor / Manager Workflow

  • Use Timelines to see when and why machines stopped.

  • Review downtime totals per shift, job, or category in Downtime Reports.

  • Monitor real-time machine states across the floor using Dashboards.

  • Use ADT rule output to eliminate recurring stoppages and reduce operator classification workload.

Configuring ADT Rules

Rules are created in the Auto Downtime Lab. Each rule includes:

  • A trigger mode (State, Alarm, Alarm-message, IO, Time-based, Setup)

  • A comparison

  • A value

  • A downtime category to apply when conditions match

  • A Setup or selected Setup Activity Types

Rules can be stacked to create complex logic.

Machine State Example

Use case: Categorize downtime as Operator | Single Block when Single Block mode is active.

Rule Setup:

  • Mode: State

  • Target: single-block

  • Value Compare: equals

  • Value: 1

  • Downtime Category: Operator | Single Block

Alarm Number Example

Use case: Categorize downtime as Machine Fault | Programming Error when alarm PS1 occurs.

Rule Setup:

  • Mode: Alarm

  • Target: PS1

  • Value Compare: equals

  • Downtime Category: Machine Fault | Programming Error

Alarm Text Example

Use case: If the alarm text contains “Overload,” classify downtime as Machine Fault | Overload.

Rule Setup:

  • Mode: Alarm-message

  • Value Compare: contains

  • Value: Overload

  • Downtime Category: Machine Fault | Overload

IO / PLC Signal Example

Use case: When the door interlock is open, classify downtime as Operator | Door Open.

Rule Setup:

  • Mode: State

  • Target: door-open

  • Value Compare: equals

  • Value: 1

  • Downtime Category: Operator | Door Open

Supporting reference for locating IO addresses, such as door interlock X9.1:

Time-Based Trigger Example

Use case: Categorize downtime as Break from 10:30–10:45 AM, Monday–Friday.

Adapter YAML (from ADT PDF):

version: 2
generators:
  flag-morning-break:
    type: cron
    cron: "0 30 10 * * 1-5"
    duration: 15m
    timezone: America/New_York

variables:
  adt-break:
    - expression: flag-morning-break == true ? 1 : 0

data-items:
  - adt-break

Rule Setup:

  • Mode: State

  • Target: adt-break

  • Value Compare: equals

  • Value: 1

  • Downtime Category: Break

Setup / Setup Activity Type Examples

These rules allow classification tied to machine setup workflows.

Use case: Categorize all setup-related downtime as Setup | In Progress.

Rule Setup:

  • Mode: Setup

  • Value Compare: equals

  • Value: Any

  • Downtime Category: Setup | In Progress

Use case: Categorize downtime during First Piece Inspection as Quality | First Piece Inspection.

Rule Setup:

  • Mode: Setup

  • Target: (Setup Activity Type)

  • Value Compare: equals

  • Value: First Piece Inspection

  • Downtime Category: Quality | First Piece Inspection

Additional Rule Properties

  • Active Seconds to Ignore
    Prevents rules from firing during very short state changes.
    (Example: machine briefly cycles then stops again)

  • Strict Modes

    • Off — Applies to the full duration of a downtime

    • Strict Start — Starts downtime category immediately when trigger activates

    • Strict End — Ends the category exactly when trigger ends

    • Strict — Precise start and stop tied directly to the trigger’s active window
      Ideal for scheduled breaks or clearly bounded events.

Understanding Downtime Categories

A downtime category describes why the machine stopped.

Downtime categories may represent:

  • Mechanical faults

  • Tooling issues

  • Material shortages

  • Operator-driven actions

  • Program stops (e.g., M0 Active)

  • Setup processes

  • Any custom classification needed for reporting accuracy

ADT rules ensure these reasons are assigned consistently and automatically—without relying on operators.

Tips & Best Practices

  • Observe your machine for native codes and items that can be used as triggers

  • Keep rules simple—use the minimum set of triggers required.

  • Place high-value, repeatable events into ADT rules to reduce manual entry.

  • Use Strict mode for events with precise boundaries (breaks, meetings).

  • Regularly review downtime reports to validate rule behavior.

  • Maintain signal documentation (PLC addresses, mapped data items).

  • Use the new Setup trigger for more accurate categorization during setup-related work.

FAQs & Troubleshooting

Does ADT detect downtime automatically?
Yes. MachineMetrics detects machine idle states automatically; ADT assigns the category.

Do I need operator input?
Only if you choose to enable manual downtime reason selection.

Can I categorize downtime based on alarms?
Yes. Rules can match alarm number or alarm text.

Where do I find PLC signal addresses?
In the machine’s PLC ladder or wiring diagram. Inputs typically use X registers and outputs Y.
Include them in your Data Map and MachineMetrics can map them for you.

What happens if the machine briefly runs then stops again?
Use Active Seconds to Ignore to avoid misclassification.

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