- 8.0 Introduction
- 8.1 Excessive Downtime Report
- 8.2 Summary Report
- 8.3 Lost Time
- 8.4 Raw Cycle/Telemetry Data
- 8.5 Historical Runs
- 8.6 Historical Status Logs
Reports are designed to provide actionable data for production meetings, initiatives and analysis. New reports are added periodically, so it is best subscribe to email updates from LCM2M that announce new features.
8.1 Excessive Downtime Report
The Excessive downtime report shows each instance where a piece of equipment was down for longer than allowed, and that threshold is configurable. Excessive downtimes are intended to capture gaps in equipment utilization that start to effect operational efficiency. The Excessive downtime report shows the total number of hours included in excessive downtime occurrences, and the rest of the report breaks down where and how they occurred. There are several parts to this report, and those are outlined below.
- Bar chart – This chart shows excessive downtime occurrences or hours broken out by downtime reason. These reasons are configurable, and are assigned in the table shown in #2. There is a little more detail on this chart below.
- Show chart – Unchecking this checkbox will hide the bar chart marked by #1. The table (#2) will be the only part of the report that will be shown.
- Sort by – This will only effect the chart. If this is set to Occurrences, the reasons in the chart will be sorted by the number of times the reason occurred, sorted from most to least. If this is set to Total Hours, the reasons in the chart will be sorted by the number of hours associated with each reason, sorted from most to least.
- Downtimes table – This table displays excessive downtime entries and allows a user to enter downtime reasons for each entry. The next 8 entries describe the parts of the table.
- Equipment – The name of the equipment that the excessive downtime occurred on.
- Status – This is included as a reminder that this is a downtime report and will always show Down. Shows the status when the excessive downtime occurred.
- Start Date – The time and date when the downtime entry was opened/created.
- End Date – The time and date when the downtime entry, which became excessive, was closed.
- Duration – The length of the excessive downtime entry, formatted in hours, minutes and seconds to be easily read and referenced.
- Reason – This column holds drop down menus which allow users to specify why the equipment was down for an excessive amount of time. These reasons are configurable, and changing them is explained in the Configuration section of this user guide. Once the reason has been set, the excessive downtime entry will be saved, and the information for the entry will be used in the chart marked as #1. See the default list of reasons below this section.
- Notes – Hovering the mouse cursor over the Notes field of an entry will display a edit (pencil icon) button. Clicking that button will add a text field that notes can be entered into. These notes are stored with the excessive downtime entry, and are used to add clarification above and beyond the downtime reason.
- Ignore – If an excessive downtime entry was recorded and is not a concern, clicking the Ignore button on the entry will remove the entry from the table.
- Search field – Typing in this search field will filter the entry list based on the Equipment, Reason, and Notes field.
- Show ignored/Show previously marked – If an entry has had its Ignore button clicked, it can be displayed again by checking the Show ignored checkbox. If an entry has had its Reason set, it can be made visible again by checking the Show previously marked checkbox. This is useful when changing a downtime entry’s reason is desired.
- Export – Clicking this button shows JSON and CSV buttons that determine what format the data shown in the table is downloaded in.
The reasons for excessive downtimes are configurable, but there is a set of default reasons. The default reasons are as follows.
- Man (i.e. there was no operator)
- Machine (i.e. the equipment was in need of repair)
- Method (i.e. an operator cannot keep a piece of equipment running due to not having the proper tools)
- Material (i.e. no material was available to run the part)
- Schedule (i.e. the equipment was not scheduled to run, or was scheduled incorrectly)
- Prev. Maintenance (preventative maintenance was being done on the equipment)
As downtime reasons are set in the report, the bar chart at the top of the report will begin to populate. There are two indicators for each reason. The purple bar is the number of occurrences (or total hours) of the reason. The green line is the number of total hours the equipment was down for that reason. This chart can be hidden at any time by un-checking the Show chart checkbox.
The Configuration section explains how to define the excessive downtime threshold on a piece of equipment so that this report is meaningful for your organization. It also provides information on how to configure custom downtime reasons.
8.2 Summary Report
The Summary Report option is only available above the equipment level in the company tree hierarchy, and reports on data from the current level down to the bottom of the company tree. The sections of the Summary Report are outlined below. Utilization color coding follows the pattern outlined in the Overall Utilization section.
- Takes the utilization metrics from all equipment below the current level in the company tree, and combines them into one value.
Below the overall percentage value is an indicator showing the hours run versus the hours scheduled.
- Shows a breakdown of each group (department, facility, etc) directly below the current level in the company tree.
This makes it easy to determine how departments and facilities are performing compared to each other.
- Equipment Exceptions: When the No recent cycles(>=2d) tab is selected, devices on equipment that have not reported in for at least the last 2 days are listed.
Reasons for this can vary. Equipment can be powered down for maintenance, thus shutting off power to a device, or a device might have a network connection issue.
This list can be used to help a maintenance department triage devices that need attention.
When the Underutilized(<80%) tab is selected, pieces of equipment that are showing less than 80% utilization are listed.
- Excessive Downtimes: Shows the number of hours associated with excessive downtime in each department/facility below the current level in the company hierarchy.
The threshold defining what constitutes excessive downtime can be set via the instructions in the Configuration: Managing Equipment section this user guide.
This information can be used to determine which facilities, departments, workcells, etc to focus on, but is very dependent on the type of equipment in a facility.
For instance, a CNC machine shop will typically have a smaller number of excessive downtimes than a molding operation that involves several manual steps by an operator.
Therefore, groups of equipment cannot always be directly compared. Hovering your mouse cursor over each bar in this chart will show a tool tip with the hour values.
- Downtime Reasons: Pie chart showing the distribution of reasons why equipment was down. This chart depends on information provided by users in the Excessive Downtime report.
A legend is provided on the right, showing the reasons that users are allowed to enter. Hovering your mouse cursor over each slice in the pie chart will display the number of times that a reason was selected as being the cause of the excessive downtime.
8.3 Lost Time
The Lost Time report is only available above the equipment level in the company tree hierarchy, and shows the amount of time lost due to slow startups and early shutdowns on shift starts, ends, and breaks. This report is generated for the current week and is broken down by shift, but requires that a schedule be defined with shifts for the department and the equipment below it. If no shifts are defined, the report will not display any data.
Some points of interest in the report are numbered, and the significance of each is outlined below.
- Shift tabs – By default, data for all shifts is displayed in the bar chart and table. If a tab for a specific shift is clicked, only the data for that shift will be displayed.
- Bar chart – Shows a bar for each shift on each day of the current week. If a specific shift tab is selected, bars for only that shift will be shown. Hovering the mouse cursor over the bars will display the numerical values for each bar.
- Day tabs – By default, the table will display data for the first day of the week. Other days can be selected to display their data in the table.
- Lost time table – This table displays the machines with lost time, and shows bars indicating when they started and ended. The color code explaining normal, late/early, and excessively early starts and shutdowns is noted by #5. If a shift has not completed yet, its entry will have an icon like the one shown by #6.
- Color legend – These are colors which are defined for the table entries and not for the bar chart. Yellow means that a late start or early shutdown occurred, but did not cause an excessive downtime entry to be created. Red means that a late start or early shutdown did cause an excessive downtime entry to be created.
- Open shift icon – A shift entry with this icon is showing that the shift being displayed has not ended yet.
8.4 Raw Cycle/Telemetry Data
The raw cycle data report is only available when at the equipment (lowest) level in the company hierarchy. Below is a labelled screenshot with descriptions of each field.
- Data type – There are two types of data available in this report: Cycle and Telemetry. Cycle data will always be available, but Telemetry (polled data) has to be enabled for the device on the selected piece of equipment. By default, All is selected on this control which displays both types of data. When Cycle is selected, only Cycle data will be displayed. When Telemetry is selected, only Telemetry data will be displayed. Whatever the Data type filter is set to will determine what data is exported when clicking the Export button marked by #8.
- Type – This field denotes whether the a of data is Telemetry data or Cycle data.
- Occurred At – This field shows what time the cycle occurred at.
- Cycle Time – The cycle time associated with a Cycle will be shown here. Telemetry data will not show a cycle time as it is polled data.
- Temperature – This displays the temperature data from an installed thermocouple. If no thermocouple is installed a dash will be shown instead of a numeric value.
- Analog In – Displays the analog value, with scaling applied. If nothing is connected to the analog port on the device, this value will be 0.00. Exporting the data via the Export button marked with #8 will include both the raw and scaled analog values in the resulting file.
- Tag(s) – If a run was active when the cycle was recorded, the tag(s) associated with the run will be included in this column, and will be included in the exported data saved via the export button (#8).
- Export – Clicking this button will allow a user to choose between JSON and CSV formats, and then will automatically download the file via the browser. This allows the data from the table to be downloaded for further analysis in applications such as Excel and Minitab.
8.5 Historical Runs
The Historical Runs report is only available at the equipment level of the company tree hierarchy. Clicking Historical runs under Insights in the right sidebar displays the report. Below is an annotated overview of the report.
- Start Date – The time and date that the run was created.
- End Date – The time and date when the run was completed by reaching the # Parts Desired metric from #5 if allow overrun was left unchecked when the run was created. If allow overrun was checked, the End Date is when a user closed the run manually.
- Duration – A human readable duration that specifies the days (d), hours (h) and minutes (m) that the run was active.
- Tag(s) – A list of any tags that were defined for the run when it was created, which can represent free-form information like part numbers and operator identification.
- # Parts Desired – The number of parts that were specified for the run when it was created. If allow overrun is unchecked when the run is created, the run will be closed when this number of parts is reached.
- # Parts Actual – The number of parts that have been created according to the number of cycles that the Caddis device has detected. If allow overrun was unchecked when the run was created, this should be the same as # Parts Desired unless a user closed the run manually. If allow overrun was checked, this number could be larger or smaller because a user has to close the run manually.
8.6 Historical Status Logs
The historical status logs report is essentially a tabular version of the barcode chart on the equipment detail page. Clicking Historical status logs under Insights in the right sidebar displays the report. Below is an annotated overview of the report.
- Log type – A set of buttons that filters the status log entries. The options are All (shows Running and Down), Running (shows only Running entries), and Down (shows only Down entries).
- Status – Indicates whether the status entry was representing a Running or Down condition.
- Start Date – The time and date when the status log was created.
- End Date – The time and date when the status log was closed by the start of a new different status.
- Duration – A human readable duration of the status in days (d), hours (h), minutes (m), and seconds (s). This is the length of the status entry from the Start Date to the End Date.
- Export – Clicking this button allows the user to choose whether they want to download the table’s data in either JSON for CSV format. This makes it easier to analyze the data in external programs such as Excel or Minitab. Clicking either the JSON or CSV buttons that appear will automatically download the data in that format.