To collect and analyze machine downtime data for 12 operations across two shifts on an engine machining line.

Evaluate and compare data to determine throughput losses between shifts, confirm hourly production counts and determine reasons for lost production, determine top 10 downtime causes by station based on minutes and occurrences, and make recommendations to reduce machine downtime.

At the start and end of each shift, IET engineers checked the specified tool set-ups. Production counts were recorded for each machine each hour. Detailed causes for lost production were recorded including: blocked times, starved times, gauging times, tool changes, self-induced downtime, response times, and rejected or scrapped parts.

Documented details were summarized by operation and charts developed outlining reasons for lost time during the observed shifts. Pareto charts were generated to show all operations ranked by total downtime, blocked downtime and starved downtime. Stacked bar charts were developed to show all downtime for all operations.

IET engineers developed operation specific solutions and assisted the client staff in implementing these solutions to increase and maintain production levels.