Breakdowns raised from the floor, spares and technician time costed
When an operator stops a machine at the terminal for a breakdown reason, a repair request opens for that machine at once. The maintenance team is told. The stop time and the repair sit on one record, and the repair is costed in spares and technician time.
PLANSFrom Growth
The problem it solves
- A machine stops, the operator waits, and maintenance hears about it an hour later from the supervisor.
- Downtime is written in a register that nobody adds up, so the same machine fails every month.
- Repairs are done with spares from the store and nobody records which machine they went to.
- You cannot say what breakdowns cost you in a month.
How it works
- Mark the stop reasons that mean a breakdown with the Breakdown switch, for example Equipment Failure.
- Link each piece of equipment to its machine or station.
- At the terminal the operator presses Stop and picks the reason. If it is a breakdown, a corrective request opens for that machine's equipment, at the highest priority, linked to the stop.
- The request's technician, or else every Maintenance Technician of the Entity, is told at once. A technician can also take it from the app's Repairs.
- The technician fixes it, issues the spares used and closes the request. The request is costed, and the machine is restarted at the terminal.
Everything it does
Raised from the terminal
- Only stop reasons marked Breakdown raise a request; other stops (material, setup) do not
- The request is named Breakdown: equipment (reason), with the operator's note, or Stopped at the terminal by the operator's name
- Corrective, priority 3 (the highest), scheduled now, linked to the Machine Stop record
- No second request while a corrective request for that equipment is still open
- Nothing is raised for a machine with no equipment linked to it
- A supervisor stopping a machine from the app's Jobs raises the same request
On the request
- Machine Stop: the stop it came from, so the downtime and the repair are on one record
- Spares Used and Issue Spares: a stock transfer to a Spares Used location
- Cost: Spares plus Technician Time (duration at the Entity's technician cost per hour), worked out when it reaches a done stage
- Checklist lines can be added by hand
Seeing it
- Maintenance dashboard: open breakdowns, open requests by machine, requests per day
- An andon call of kind Maintenance (Growth) tells the maintenance people too, separately from the request
- OEE (Scale) counts the stop time as lost availability
Who uses it
OperatorStops the machine at the terminal with the reason, and restarts it when it is fixed.
Maintenance TechnicianGets the request, repairs the machine, issues spares and closes it.
SupervisorCan stop and restart machines from the app's Jobs, and follows open breakdowns.
Manufacturing AdministratorMarks which stop reasons are breakdowns and links equipment to machines.
Where you use it
- Web: the shop floor terminal (Stop with a reason), on a tablet's browser
- Web: Maintenance Requests, with the machine stop, spares and cost
- The SmartMy Manufacturing app: Jobs (stop and restart a machine, for supervisors) and Repairs (for technicians). Built and in testing, not in the app stores yet
What you control
Settings
- Breakdown: a switch on each stop reason, off to start with
- Technician cost per hour: Settings > Manufacturing, empty to start with
Notifications
- Maintenance Request: to the request's technician, or else every Maintenance Technician of the Entity, the moment a breakdown request opens. In the app inbox and by email (app push built in, not switched on yet). A person can switch off email but not the event
Questions
Does every stop open a repair request?
No. Only stop reasons you mark as Breakdown do, and only when the machine has equipment linked to it.What if the machine stops twice before it is fixed?
No second request opens while a breakdown request for that equipment is still open.Who is told?
The technician on the request, or else every Maintenance Technician of the Entity, at once, in the app inbox and by email.Can we see the cost of a breakdown?
Yes. Once closed, each request shows its spares at stock value and the technician time at your rate per hour.Do operators need a login?
No. Operators use the terminal with their badge or PIN; the tablet is signed in once as an Operator user.Related features
PLANNING, QUALITY AND COSTPreventive maintenance by days, hours or cyclesEach machine gets maintenance plans that fall due by the calendar, by its running hours or by the pieces it has made. A due plan raises a maintenance request with its checklist and spares, and closing the request costs it and moves the plan on.SHOP FLOORThe shop floor terminal: a tablet at each machineA tablet at each machine or station shows its jobs in big tiles. Operators sign in with a PIN or badge, and start and pause jobs. They count good and rejected pieces with a reason, and stop the machine with a reason. Every count goes straight into the order.SHOP FLOORAndon: calls for help and the andon boardAn operator presses Call on the terminal and picks who is needed: a supervisor, maintenance, quality or material. The people of that kind are told at once. The andon board shows every call waiting and being handled, with the minutes it waited and took to fix.LINES AND SCHEDULINGOEE per machine and day, and the machine board on a TVOEE is worked out every hour for each machine and day from its running time and the pieces counted at the terminal. It is split into availability, performance and quality. A machine board on a TV shows every machine as working, stopped or idle.PLANNING, QUALITY AND COSTThe SmartMy Manufacturing appAn Android and iOS app for supervisors, quality inspectors and maintenance technicians. It has today's figures, production orders, machines and jobs, andon calls, quality checks and repairs. Each is shown to the people whose role allows it. Operators keep working on the terminal.ACROSS SMARTMY MANUFACTURINGDashboardsManufacturing opens on ready dashboards for each role. The supervisor sees what is running and waiting for material, and the planner sees the order book. Job work, quality and maintenance each have their own. Every number is counted for the person looking, and a click opens the records behind it.
See your shop floor on it.
Tell us what you make, how many machines and people you run, and how production is recorded today. We will set up a line with you and run a job on the terminal.