The Essential Guide to Machine Downtime Tracking

Why You Must Track Every Stop

Downtime—any period when a machine is expected to be running but isn’t—is the single biggest drain on manufacturing profitability. The issue is that most factories significantly underestimate their true downtime because they rely on inconsistent, manual logs.

This guide provides a starting point: a structured, manual approach using Excel. But more importantly, it shows the hidden losses that only automatic tracking can uncover.

Understanding the Three Types of Downtime

• Planned Downtime: Essential, scheduled stops like maintenance, cleaning, setup (SMED), or mandatory tool changes. These are predictable and necessary.
• Unplanned Downtime: Unscheduled events like breakdowns, operator errors, material shortages, or quality holds. These are the main targets for immediate improvement.
• Micro-stops: The invisible loss. Very short interruptions (often 5 to 30 seconds) that an operator may not log but which collectively reduce output by hours per week. This is the critical difference between manual and automatic tracking.

Start Simple: Manual Tracking with Our Free Excel Template

Manual tracking is the perfect first step. It forces teams to establish a process, create standard reason codes, and build the habit of recording machine states.

Key Data Points for a Manual Log

• Machine & Operator: Who, where?
• Start & End Time: For accurate duration calculation.
• Downtime Reason: The most crucial data point for root cause analysis.
• Categorization: (e.g., Mechanical, Electrical, Changeover, Other).

Our free template provides this structure, with easy dropdown menus and automatic calculation.

The Problem: Manual Tracking Hides The True Loss

While Excel is a great start, it inherently provides an inaccurate picture. Operators focus on running the machine, not logging data, leading to a huge data gap.

What Manual Logs Miss (The Hidden Factory)

• The 15-Second Delay: Operators will never log a 15-second jam, but 20 of those per shift is 5 minutes lost per hour.
• Forgotten Stops: Downtime events that occur during high-pressure moments are often simply forgotten.
• Subjective Coding: Reasons are often simplified or misclassified due to lack of time or operator bias.
• Speed Loss: Manual tracking provides zero insight into a machine running at 80% speed.

Manual Data shows your Perceived Downtime.
Automated Data shows your Actual Downtime.

The Next Step: Automated Downtime Tracking

When you move from Excel to a real-time system (like HOPIT), machine data is collected directly from sensors and PLC, eliminating human error and revealing the true rhythm of your production line.

Manual vs. Automatic Tracking Comparison

When to Make the Switch

• Your Excel data shows an OEE you don't fully trust.
• You consistently struggle to find the root cause of frequent, small production bottlenecks.
• You need an accurate benchmark for continuous improvement programs (like Lean or Six Sigma).
• You want to eliminate manual data entry effort entirely.