Total time per day 24 hours

x
Total number of days per year 365 days
= Loss
Loss
(as a percentage of the
Total time per year 8760 hours (as a percentage of the
total time in a 365 day-
total time in a 365 day-
year)
year)

Number of days closed per year

(holidays, weekends, etc.) 28 days 7.67 %

Number of shifts per day 2

Length of shifts 7.5 hours 34.62 %

Planned downtime per day

(downtime accounted for in the
production schedule, e.g. shop floor
45 min 2.89 %
meetings, breaks, scheduled
maintenance, etc.)

Time not available per year 3957.75 hours 45.18 %

Remaining
Remaining
availability
availability

Time available per year 4802 hours 54.82 %

Time available per workday 14.25 hours

855.0 min

Next
Next
 Do you want to Yes
Machine ID AB12
include setup time? No

Now we need some details about the production parameters. If we

ask for the time per day we mean a workday with the available time
as calculated in the previous sheet. Loss
Loss
(as a percentage of
(as a percentage of
Natural process time the total time in a
the total time in a
workday)
workday)
What is the natural process time of the product on 23 min/product
this machine?
Downtime

What are the MTTF and MTTR of this machine?

MTTF 6000 min
Only count the time lost during workdays. 4.76 %
MTTR 300 min

Minor stoppages

How many times per day is the production stopped

for small problems. E.g. due to a blocked machine, 7 times
a safety stop, a defective product that has to be
removed etc. 4.91 %
6 min
How long does an average stop take?

Rework
How many products have to be reworked per day 0.5 products
due to quality problems? 1.46 %
How much time does it take to rework one
product?
25 min

Prototyping
How much time is lost per day on the production of 2 min 0.23 %
prototypes and test products?
Worker/machine interaction
How much time is lost per day because no 23 min 2.69 %
operator is available?

Material/machine interaction
How much time is lost per day because of material 20 min 2.34 %
shortages?
Setup
What lotsize is used for this product? 0 products

How many setups per day are there on this

machine? 0 setups
0.00 %
What is the setup time? 0 min

How much time is lost after a setup before the first

good product is produced?
0 min

Results
Results
 Results

natural process
time
23.00 min

Per type of outage Cumulative

100 % Per type of outage Cumulative
downtime 4.76 % 95.24 % 1.31 min 24.31 min
minor stoppages 4.91 % 90.33 % 1.35 min 25.66 min
rework 1.46 % 88.86 % 0.40 min 26.06 min
prototyping 0.23 % 88.63 % 0.06 min 26.13 min
worker/machine int. 2.69 % 85.94 % 0.74 min 26.87 min
material/machine int. 2.34 % 83.60 % 0.64 min 27.51 min
setup 0.00 % 83.60 % 0.00 min 27.51 min
16.40 %
effective process
time 1
27.51 min

Availability per
workday
83.60 %

Time available per

year 54.82 %

Availability on a effective process

yearly basis
45.83 % time 2
50.19 min

total time per year

525600 min
(365x24x60)
effective time used
240883 min
per year

Graph
Graph
 AB12
Effective process time of machine

effective process time 2

effective process time 1

setup
material/machine int.
worker/machine int.
prototyping
rework
minor stoppages
downtime
natural process time

0 10 20 30 40 50 60
minutes
Process times Losses