24 hours

Total time per day

365 days

Total number of days per year

8760 hours

Total time per year

Number of days closed per year

(holidays, weekends, etc.)

28 days

7.67 %

Number of shifts per day

7.5 hours

Length of shifts
Planned downtime per day
(downtime accounted for in the
production schedule, e.g. shop floor
meetings, breaks, scheduled
maintenance, etc.)
Time not available per year

Loss
Loss

(as a percentage of the

(as a percentage of the
total time in a 365 daytotal time in a 365 dayyear)
year)

45 min

3957.75 hours

34.62 %

2.89 %

45.18 %

Remaining
Remaining
availability
availability
Time available per year

Time available per workday

4802 hours

14.25 hours
855.0 min

Next
Next

54.82 %

Machine ID

Do you want to
include setup time?

AB12

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.
Natural process time

23

What is the natural process time of the product on

this machine?

min/product

Loss
Loss

(as a percentage of
(as a percentage of
the total time in a
the total time in a
workday)
workday)

Downtime
What are the MTTF and MTTR of this machine?
Only count the time lost during workdays.

MTTF

6000

min

MTTR

300

min

4.76

4.91

1.46

Minor stoppages
How many times per day is the production stopped
for small problems. E.g. due to a blocked machine,
a safety stop, a defective product that has to be
removed etc.
How long does an average stop take?

times

min

Rework
How many products have to be reworked per day
due to quality problems?

0.5

products

How much time does it take to rework one

product?

25

min

min

0.23

23

min

2.69

20

min

2.34

What lotsize is used for this product?

products

How many setups per day are there on this

machine?

setups
0.00

Prototyping
How much time is lost per day on the production of
prototypes and test products?
Worker/machine interaction
How much time is lost per day because no
operator is available?
Material/machine interaction
How much time is lost per day because of material
shortages?
Setup

What is the setup time?

min

How much time is lost after a setup before the first

good product is produced?

min

Results
Results

Yes
No

Results
natural process
time
Per type of outage
downtime
minor stoppages
rework
prototyping
worker/machine int.
material/machine int.
setup

4.76
4.91
1.46
0.23
2.69
2.34
0.00
16.40

%
%
%
%
%
%
%
%

Availability per
workday
Time available per
year

Availability on a
yearly basis
total time per year
(365x24x60)
effective time used
per year

Cumulative
100 %
95.24 %
90.33 %
88.86 %
88.63 %
85.94 %
83.60 %
83.60 %

83.60

23.00 min

Per type of outage

1.31 min
1.35 min
0.40 min
0.06 min
0.74 min
0.64 min
0.00 min

Cumulative
24.31 min
25.66 min
26.06 min
26.13 min
26.87 min
27.51 min
27.51 min

effective process
time 1

27.51 min

effective process
time 2

50.19 min

54.82 %

45.83

525600 min
240883 min

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

10

20

30

minutes
Process times

40

Losses

50

60