Skip to main content

Downtimes

What is Downtimes?​

Downtimes is where you configure downtime categories (reasons) and general downtime settings.

Access: Settings → Downtimes

Who Can Manage: Managers, Executives, IT Admins

General Downtime Settings​

Access: Settings → Downtimes → General

Key Settings:

1. Microstop Duration (seconds)​

Purpose: Threshold separating microstops from long downtime.

Configuration:

  • Enter duration in seconds (e.g., 60)
  • Default: 60 seconds

Impact:

  • Downtime < threshold: Categorized as "Microstop"
  • Downtime ≥ threshold: Categorized as "Long Downtime"

Reporting:

  • Microstops typically excluded from downtime reports
  • Long downtime requires categorization

2. Downtime List Filter (seconds)​

Purpose: Hide very short downtime events from operator categorization list.

Configuration:

  • Enter duration in seconds (e.g., 30)
  • Default: 30 seconds

Impact:

  • Downtime < filter: Hidden from operator's categorization list on tablet
  • Prevents operators from being prompted to categorize very short stops

Example:

Downtime List Filter: 30 seconds

5-second stop: Hidden (not prompted)
45-second stop: Shown (operator can categorize)

3. Unattended Inactive Threshold (minutes)​

Purpose: For unattended shifts, determines when idle time becomes unscheduled.

Configuration:

  • Enter duration in minutes (e.g., 30)
  • Default: 30 minutes

Impact:

  • During unattended shifts, if machine idle > threshold:
    • Time becomes unscheduled (doesn't affect Availability)
  • If machine idle < threshold:
    • Time remains scheduled (affects Availability)

See Also: Machine Schedules and Understanding Your Data Guide

4. Exclude Planned Downtime from Production Metrics​

Purpose: Exclude planned downtime (breaks, PM, etc.) from Availability and Performance calculations.

Configuration: Toggle on/off

Impact When Enabled:

  • Planned downtime subtracted from scheduled time
  • Does not hurt Availability or Performance
  • Still included in Quality calculation

Impact When Disabled:

  • All downtime (planned and unplanned) affects Availability equally

Example:

Scheduled Time: 8 hours (480 minutes)
Planned Break: 30 minutes
Planned Maintenance: 60 minutes

If Enabled:
Scheduled Time = 480 - 30 - 60 = 390 minutes

If Disabled:
Scheduled Time = 480 minutes (breaks/PM hurt Availability)

General Downtime Settings

Downtime Categories​

Access: Settings → Downtimes → Downtime Categories

Purpose: Define reasons for downtime that operators select in ShopPulse and automatic downtime rules assign to events.

See Also: Downtime Guide for category management, or Automatic Downtime Categorization to assign these reasons using rules

Start with a small set of broad reasons unless you are replicating an established downtime tracking system. Choose categories for the losses you need to compare in reporting, then add detail as needed. See Choosing Your Initial Categories before building a hierarchy.

Creating Downtime Categories​

Step-by-Step:

  1. Navigate to Settings → Downtimes → Downtime Categories
  2. Click "Add Category"
  3. Enter Category Name
  4. Select Planned/Unplanned Behavior:
    • Planned or Unplanned: Operator chooses
    • Unplanned: Always unplanned
    • Planned: Always planned
    • Planned with Limit: Planned up to X minutes, then unplanned
  5. Select Color (for visual identification)
  6. Click "Save"

Creating Hierarchical Categories​

Purpose: Nest categories for more specific root cause tracking.

Format: Use pipe (|) separator

Example:

Parent Category: Tooling
Child Category: Tooling | Tool Change
Grandchild Category: Tooling | Tool Change | End of Life

Steps:

  1. Create parent first: Tooling
  2. Create child: Tooling | Tool Change (note the space before and after |)
  3. Create grandchild: Tooling | Tool Change | End of Life

Important: You must create each level separately.

In Settings, there is an example showing the correct format with the vertical space bar character (|).

Planned with Limit​

Purpose: Mark downtime as planned up to a certain duration, then unplanned if it exceeds.

Example:

Category: Operator Break
Behavior: Planned with Limit
Limit: 15 minutes

Scenario:
Break duration: 10 minutes → Planned (OK)
Break duration: 20 minutes → 15 min planned, 5 min unplanned (excess)

Use Case: Allow reasonable breaks without affecting OEE, but flag excessive breaks.

Colors​

Purpose: Visual identification on tablets, timelines, and reports.

Best Practice:

  • Use consistent colors for related categories
  • Example: All "Maintenance" categories = orange, all "Material" categories = blue

Operator View: Colors appear on:

  • Operator Dashboard (tablet)
  • Timeline visualization
  • Downtime reports

Assigning Categories to Machine Groups​

When creating/editing Machine Groups:

  • Select which downtime categories apply to that group
  • Only selected categories appear on tablets for machines in that group

Example:

Group: CNC Mills
Categories: Tool Change, Setup, Material Unavailable, Maintenance

Group: Manual Welding
Categories: Waiting for Welder, Material Unavailable, Electrode Change

Operators on CNC Mills only see the 4 categories relevant to mills.

Downtime Categories list and creation form