Equipment Downtime Reduction Methodology

1:- Create a process map of all the equipment

Machine A Machine B Machine C Machine D Machine E

2:- Record the actual downtime for each of the machines in the process map, if possible can data from previous years be included to evaluate the
trend. Also collect production volume data to compare downtime against volume.

22000
Machine Machine Machine Machine Machine
Volume
A B C D E
16500
2013 3396 1289 5654 7121 1178 5500000

2014 3991 925 6932 6006 1045 5800000 11000

2015 2774 803 6554 7200 986 6200000

5500
TOTAL
10161 3017 19140 20327 3209 17500000
DT
0
2013 2014 2015 TOTAL DT
3:- List all the different failures that have occurred at each of the items of equipment, look to utilise a photo or diagram of the equipment so as to be
able to indicate where on the equipment the failures are taking place. This will allow you to create a cluster diagram to highlight where most of the
problems are taking place.

This represents a diagram of a spiral conveyor used to transfer the

Spiral Conveyor Failure Points
product from ground floor to the upper level where the product will
be fed into the packing machines.

The failure data for the spiral conveyor has been reviewed and from
it identified to individual areas or items on the spiral conveyor and a
dot shows each individual failure. From the diagram it can be seen
that the highest number of failures occurs at the tensioning area for
the conveyor.

What is is important to remember is that the number of failures is

important, however its important to also identify the time lost for the
failures because you can have six failures but the total time lost
could be 30 mins, but the motor gearbox which only has three
failures that could equate to 12 hours so the area to target to reduce
downtime is the motor gearbox as this generates the largest
downtime.