Implementing Standard Work is a fundamental element of any improvement
project. However, problems arise in daily operations that prevent people from
achieving the standard work.
The Downtime Tracking tool is designed as a means for people working in the
area to capture the reasons why the Standard Work could not be achieved.
Though it includes equipment “downtime” it is any reason Standard Work could
not be attained and how much time was lost. Those reasons are then
automatically charted enabling you to understand the top one or two causes and
focus your future improvement activities. After putting corrective action in place
the next most prevalent downtime causes can be attacked.
To be effective, Downtime Tracking should be implemented in the work area
readily accessible by all those required. Immediate and longer term
countermeasures to the problems identified should be tracked and
communicated to those encountering the downtime. It is recommended that you
use your Task List on an ongoing basis to accomplish this.
Before using the Down Time Tracking tracking tool, it needs to be configured with
an initial list of down time reasons. Additionally, a schedule with at least one shift
must be setup (see Capacity and Scheduling). Note that the schedule and shift
do not need to be fully populated with demand counts by hour for down time
tracking to work.
How To Use
1. Down Time Tracking can be accessed on the project panel's Sustain tab. To
configure down time reasons, click the "Collect" button.
2. Click Add Reason Code.
3. Enter Reason Name, select Category and click Add.
Repeat step 3 to enter additional down time reasons.
4. To deactivate a reason that is no longer needed, select it from the drop down
list box at the bottom of the screen, clear the "Active" check mark and click
Update.
5. Define locations for Down Time events, click "Add Work Area".
6. Enter the Work Area (Location) name and click Add.
Repeat this step for additional Work Area locations.
7. To remove an existing location, use the drop-down list box at the bottom of
the block to select the work area, clear the "active" check mark and then click
Update.
8. In some cases, down time may result in rework, repair, or failure of a product
or service. These events can be tracked using Disposition Codes. Codes are
entered in the same way that Down Time Reasons and Locations are. From the
Downtime Tracking window, click the "Add Disposition Codes". Enter the name
of the disposition code and click Add. Codes can be deactivated by selecting it
from the Existing block, clearing the check, and then clicking Update.
9. To Capture a Down Time Event, click the Downtime button. This will start a
Down Time Timer (or clock) that will time how long the down time event takes.
10. At the conclusion of the event, select the Down Time Reason and Work Area
from the drop-down list boxes and then click the Resolved button. This will
capture the event and time to the data file.
11. To correct a down time entry or Over Ride the time (perhaps because the
total event time wasn't captured by the timer), click the Override Downtime
button.
12. Find the previously entered event by selecting it from the list at the top of the
screen. At the bottom of the screen, make the desired changes and click
Update. Click OK to return to the Downtime Tracking window.
13. To view Reports, click the Reports button under the Downtime Tracking
section of the main project panel's Sustain tab.
14. Select the desired number of months to display data for and the desired
chart type. The objective of the charts is to identify the high driver reasons for
down times and perform root cause analysis on them so that the waste of down
time can be reduced.
15. Charts can be printed by selecting Report | Print from the menu. Report data
can be exported to Excel (data) or PowerPoint (chart) for further analysis by
selecting Export and then the desired data.
