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Machine utilization tells you how hard your assets are actually working — not how hard you think they are. This free template gives your team a structured way to log planned vs. actual run time by machine and shift, so you can start separating true capacity from idle time, changeovers, and unplanned stops.
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Most manufacturers overestimate how productively their machines are running. Scheduled hours look full on paper, but idle time between jobs, extended changeovers, and unplanned stops quietly erode the numbers. Without a consistent log, those gaps stay invisible — and capacity planning decisions get made on assumptions rather than data. This free Excel utilization tracker gives your operators and supervisors a structured place to record actual run time, idle time, changeover time, and downtime by machine and shift. It won't replace a real-time machine monitoring system, but it will show you exactly why you need one.
Manual utilization tracking depends entirely on what gets logged — and the gaps are predictable. Short idle periods between jobs don't feel worth recording. Changeover time gets estimated rather than measured. And because operators are focused on running production, logging run states is always the last priority. A spreadsheet can't show you utilization in real time. It can't flag a machine that's been sitting idle for 40 minutes mid-shift. And it can't give you an accurate picture of available capacity until someone sits down to reconcile the data — usually too late to act on it. The result is utilization reports that look reasonable on paper but consistently undercount how much productive time is actually being lost.
Caddis Systems captures every run state, idle period, and changeover automatically — timestamped, categorized, and visible in real time on floor dashboards your operators and supervisors can see from anywhere. No manual logging. No missing the gaps between jobs. No reconciling shift reports at the end of the week to understand where your capacity actually went. If you find yourself spending more than 30 minutes a week filling out or reviewing a utilization spreadsheet, Caddis will pay for itself in the first month.
