Overview
Establishing the overall policy of auto-generating stop events is done by deciding what will be considered a micro stop (a very short stop), and what will be considered any other stop. Read more about this here. In both cases the system automatically generates a stop event. Micro stops will be automatically tagged as such, while other stops are logged without a reason and are classified manually.
By configuring a default reason for micro stops, machine operators don't have to deal with the tedious task of reporting them. All these tagged data are aggregated, which is important for analytics. For example, successive micro stops can indicate that there's an issue with the machine.
Configuring the generation of micro stop events
Go to Setup > Site Configuration > index 5 (Step 5 - Define Machine Types).
Select the applicable machine type by clicking its index number.
In the machine type's General tab > Events section:
Enter the number of minutes for Event Duration Filter (min).
This will log all micro stops up to that value. For example entering 1 minute, will log all micro events up to 1 minute as a micro event.In the Short Events Stop Reason select the stop event reason. (See below how to add stop event reasons to the system.)
Save changes.
Configuring the generation of stop events
At the machine level you choose the method and configure a threshold that determines what will automatically generate a stop event. The different methods cater to the various verticals, in which different machines and processes are used in production.
Go to Setup > Site Configuration > index 5 (Step 5 - Define Machine Types).
Select the applicable machine type by clicking its index number.
Click the Machines tab.
Select the applicable machine by clicking its index number.
In the machine's General tab > Machine Stops section > Machine Stop By list, select the method used for generating a stop event:
Number of Cycle Time Standard - the value set in the recipe of the job currently running on the machine machine's production cycle serves as the base standard for calculating that the machine stopped. This method is often chosen by verticals in which the product determines the production rate.
Fixed time (seconds) - This method is often chosen by verticals in which the machine has a fixed production pace.
Stop input from the controller - The method is often chosen by verticals in which the machine in use has a controller that provides stop input signals.
The value you enter in the Set Point For Stop field depends on the selected method:
If the method is based on cycle time, enter the number of cycles that comprise the threshold time for generating a stop event. For example if the cycle time standard is 50 seconds, entering
4as the set point, means that the stop threshold is 4 x 50 = 200 seconds, and if the machine hasn't produced anything for 200 seconds this will generate a stop event.If the method is based on fixed time, enter the number of seconds that must elapse without production to generate a stop event.
If the method is based on the stop input signal sent by the machine's controller, enter either
0or1per the signal the controller uses to indicate that the machine stopped.
Save changes.
Configuring stop event reasons
The system comes with a number of preconfigured stop event groups and reasons. Customize these groups and reasons per the client's requirements, or add new stop event groups and reasons if needed.
Adding a new stop-event group and reasons
Go to Settings > Stop Events Customization.
Click Search.
Click the add new group control.
When a group is added, by default it includes one reason.
Enter a name for the stop event group and then press to tab to advance to the reason field and enter a name for the first reason.
Configure the following parameters;
Type - stops events are considered downtime.
Color and Machine status are especially useful for color coding machines.
Machines - to which departments and machines this stop reason applies.
ERP ID - If there's an ERP ID for this stop reason, enter it here.
Active - Select this check box, otherwise this reason won't be available for use.
Op app - Select this check box to enable tagging with this stop event reason through the Operator app.
Target (%) - not applicable to stop events.
If you want to add more reasons to this stop event group:
click the add new reason control at the end of the row.
This will add another reason row that you can now fill in.
To reorder the the reasons sequence, use the dragging handle ( = ).
Click Save.
Modifying existing stop-event groups and reasons
Go to Settings > Stop Events Customization.
(Optional) Use the Machine List and Active filters to increase the search efficiency.
Click Search.
Expand the relevant event group for the stop event reason.
Click the edit icon.
Configure the parameters as described in steps 5 & 6 above.
Click Save.
Automation tips for administrators
Auto-classifying stop events with the service call context
There's an optional system setting for auto-classifying stop events. If active, the stop reason reported when opening a service call is automatically assigned to all following stop events--up to the completion of the service call.
To activate it:
Go to Setup > Site Configuration > index 5 (Step 5 - Define Machine Types).
Click the index of the machine type.
In the machine type's form click the Machines tab.
Select the machine by clicking its index number.
In the machine's form > General tab > Machine Stops section select the Classify Stop Event by Open Call check box.
Click Save Changes.
Grouping stop events under root causes in production lines
When adding a production line (Settings > Production Lines Configuration) the value set for Event duration (min) associated with root event determines the period for linking subsequent stop events to the initial stop, which is known as the root event. For example, if you set the value to 5 minutes, all subsequent machines' stops will be grouped beneath that root event up to 5 minutes after the root event ends.
NOTE
Production lines must use linking ERP jobs for root-event grouping to work.
Disabling the report stop event prompt in the Operator app
By default, stop events will trigger the report stop events dialog in the Operator app, as a best practice to prompt operators to report the reason as it happens. But if the client is interested in disabling this prompt:
Go to Setup > Site Configuration > index 5 (Step 5 - Define Machine Types).
Select the applicable machine type by clicking its index number.
Click the Machines tab.
Select the applicable machine by clicking its index number.
In the machine's General tab > Operator App section, clear the Display report screen when a new stop event occurs check box.