The plan to address unplanned downtime on the forge machine is centered around a set of key metrics that offer insights into performance and areas for improvement. By tracking Downtime Duration, we can quickly see how long the forge machine is non-operational, helping to highlight the need for maintenance and swift repairs. For example, keeping downtime below 5% ensures minimal disruption to operations.
Mean Time to Repair (MTTR) is crucial as it identifies how efficiently the machine can be brought back into service after a failure. Achieving a repair time of under 4 hours involves advanced training and streamlined processes, which directly impacts productivity. Meanwhile, monitoring Failure Frequency ensures any underlying issues are addressed before they escalate, with fewer failures contributing to smoother operations.
Downtime Costs are a pivotal metric, as they translate machine inefficiencies into financial terms. By maintaining a cost below $10,000 per incident, businesses can preserve profitability. Lastly, OEE (Overall Equipment Effectiveness) combines these elements into a comprehensive measure of equipment performance, with a world-class benchmark above 85% signifying optimization efforts are on track.
Top 5 metrics for Unplanned Downtime on Forge
1. Downtime Duration
Total time the forge machine is non-operational due to unplanned issues
What good looks like for this metric: Typically less than 5% of total operational time
How to improve this metric:- Conduct regular maintenance checks
- Invest in predictive maintenance tools
- Train staff on quick troubleshooting
- Establish a faster repair protocol
- Keep critical spare parts in stock
2. Mean Time to Repair (MTTR)
Average time taken to repair the forge machine after a failure
What good looks like for this metric: Typically under 4 hours
How to improve this metric:- Provide advanced repair training
- Streamline repair documentation
- Optimise parts retrieval processes
- Implement a 24/7 repair service
- Use diagnostic tools for accurate fixes
3. Failure Frequency
Number of times the forge machine fails unexpectedly within a specific period
What good looks like for this metric: Ideally fewer than 2 times a month
How to improve this metric:- Enhance quality control measures
- Upgrade machine components
- Perform regular performance testing
- Use high-quality materials for production
- Introduce routine inspections
4. Downtime Costs
Financial impact due to unplanned downtime, including lost production time and repair expenses
What good looks like for this metric: Generally kept below $10,000 per incident
How to improve this metric:- Budget for potential downtime
- Negotiate better rates with service providers
- Utilise insurance policies
- Invest in efficient repair technology
- Implement cost-reduction strategies
5. OEE (Overall Equipment Effectiveness)
A measure that combines machine availability, performance, and quality to assess downtime impact
What good looks like for this metric: World-class is considered above 85%
How to improve this metric:- Increase machine availability
- Enhance process efficiency
- Improve product quality standards
- Align production schedules
- Continuously monitor performance metrics
How to track Unplanned Downtime on Forge metrics
It's one thing to have a plan, it's another to stick to it. We hope that the examples above will help you get started with your own strategy, but we also know that it's easy to get lost in the day-to-day effort.
That's why we built Tability: to help you track your progress, keep your team aligned, and make sure you're always moving in the right direction.
Give it a try and see how it can help you bring accountability to your metrics.
