See our entire site devoted to the True cost of machine downtime.

TDC-Warning Data Overload!

Too many variables! Too complicated! Too much change!

These are all one time entry of constants, updated annually, exported from your existing computer systems.


These sub-categories are" per downtime" occurrence entries, but most can be exported from your CMMS.


You can use a percentage of your existing "Overhead" numbers depending on amount of TDC metrics they are made up of.

Reduced production, scrap and band-aid are less common sub-categories, and may require effort to analyze.

The irony is that every line breakdown — or at least the symptoms of a breakdown — is meticulously monitored. Every time a line is stopped, a quality inspector logs the reasons why and the length of downtime. Similarly, every hour reworking a product that wasn't done right the first time, every pound of scrap, and every unit rejected at a quality inspection gets captured in most manufacturing systems. While the data is always at hand, rarely, if ever, is it extracted from the system and presented to managers to use in an innovative and understandable fashion.

Rob Rose is vice president, product marketing, at Cognos Corporation's Burlington, Mass.

What would really be micro-analyzing:  legal liability for non-delivery, late supplier payments, depreciations and inventory stocking charges, etc.

Data collection solutions below:

First view the "Production Counting White Paper" to see how to develop your data collection process on sound principles. We want to thank ATSI for donating this valuable article.

Using MDT’s as machine data collection  “front-ends” for  MRPII, ERP, MES,  CMMS, SQC, SPC,  and bar code data collection systems. (Production Process)