How does Astn’go measure and reduce micro-downtimes?

In the manufacturing industry, equipment performance is a key factor in competitiveness. Among the main sources of productivity losses are micro downtimes, those brief but frequent interruptions that impact overall equipment efficiency and OEE.

Taken individually, these stoppages seem insignificant. However, when micro downtimes measurements are made and the times are added up over the course of a day, the picture is quite different. Astn’go plays a central role in identifying, analyzing, and reducing these downtimes. To understand how, let’s compare micro downtimes monitoring without Astn’go and with Astn’go.

Tracking micro downtimes without Astn’go

Without production follow-up software, identifying micro downtimes relies mainly on human observation and manual recording. This often leads to errors, a lack of accuracy, and limited responsiveness to problems.

Operators must manually record downtimes, which is time-consuming and can result in incomplete or inaccurate data. Analyzing the causes then becomes complex, requiring frequent audits and significant expertise to link the various parameters that influence production.

Observation:

• No regular measurement of micro downtimes
• Micro downtimes not detected or poorly detected
• Lack of accuracy
• Lack of responsiveness
• Data entry errors
• No real-time visibility
• No automatic alerts or notifications
• Difficulty obtaining accurate key performance indicators (KPIs)
• A lot of time spent on tasks that do not add value
• Lack of motivation among operators

Tracking micro downtimes with Astn’go

On the other hand, with a OEE solution, identification is automatic, reliable, and instantaneous. Thanks to sensors and real-time recording, every micro downtime is detected with precision, enabling in-depth trend analysis.

Cross-referencing data with other performance indicators makes it possible to identify underlying causes more quickly and implement appropriate corrective actions. Responsiveness is increased thanks to real-time alerts, and interventions can be planned proactively rather than reactively.

Observation:

• Removal of operator entries
• Accurate and objective data
• Comprehensive collection of micro downtimes
• The detected downtimes are reliable because they are detected directly on the machines.
• Fast and thorough data analysis
• Real-time visibility of production
• All production time is tracked and justified
• Significant reduction in human error
• Standardization of data collection
• Automatic alerts and notifications
• Accurate identification of the root causes of micro downtimes

Why should I track micro downtimes with Astn’go?

1 Identification of micro downtimes

A OEE solution such as Astn’go is equipped with IIoT sensors connected to machines, enabling real-time recording of production cycles. Thanks to configurable time thresholds, it detects the downtimes shorter than a predefined duration (e.g., 1 to 2 minutes) and classifies it as micro downtimes.

The main features for identifying these interruptions are:

• Automatic recording of downtimes: The software logs each downtime with its precise timestamp.
• Trend analysis : By identifying recurring frequencies and patterns, it highlights the equipments or processes most prone to micro downtimes.
• Real-time downtimes : Astn’go immediately alerts teams in the event of downtimes, enabling a rapid response.

2Explanation and analysis of causes

Once identified, micro downtimes must be explained in order to implement corrective actions. Production monitoring software such as Astn’go offers several analysis tools:

• Retrospective categorization of micro downtimes : Operators can report causes of stops previously defined by the manager (sensor problems, settings, lack of material, etc.)
• Correlation with other data : By cross-referencing downtimes with indicators such as production rate, changeovers, references, etc., it becomes possible to establish links between micro downtimes and other parameters.
• Reports and dashboards : Clear visualization in the form of graphs or Pareto charts allows the most frequent causes and their impact on productivity to be identified..

3 Reducing micro downtimes

The ultimate goal is to reduce these micro downtimes and improve overall performance. Several strategies can be implemented using a OEE solution such as Astn’go.

• Improvement of the production process : Highlighting the production stages most prone to micro downtimes allows for effective adjustments to be made on the production lines.
• Optimization of machine settings : Une analyse fine des données permet d’ajuster les paramètres de production pour minimiser les interruptions.
• Preventive maintenance : The history of micro downtimes helps anticipate potential failures and plan targeted interventions before a problem occurs.
• Operators formation : By identifying micro downtimes linked to human error, it becomes possible to implement specific training programs to improve practices.
• Continual improvement : Integrating micro downtime monitoring into a Lean Manufacturing or Six Sigma approach enables gradual and sustainable improvement in production.
• Performance monitoring : Thanks to automatic micro downtimes measurements, everyone can quickly identify deviations and implement corrective actions.

Conclusion

A OEE solution such as Astn’go is an essential tool for identifying, analyzing, and reducing micro downtimes. Thanks to accurate data collection, in-depth analysis, and optimization strategies, it contributes significantly to improving equipment efficiency and the competitiveness of industrial companies. Investing in a high-performance monitoring solution is therefore a strategic lever for any company wishing to maximize its productivity and minimize its losses. If you would like to estimate the profitability of Astn’go, feel free to read our dedicated article What is the return on investment with Astn’go and use our ROI calculator.

Pour en apprendre plus sur Astn’go et les gains que vous pourrez avoir grâce à la soTo learn more about Astn’go and the benefits you can gain from this solution, contact us via this link.