Downtime Analysis Plant2Business
Managing Production Efficiency Solution Paper
The efficiency of a production By automatically collecting, A Downtime Analysis system
facility is linked directly to the storing and analyzing events that needs to cope with all of these
efficiency of the individual lead to downtime, plant managers types of downtimes and report on
machinery that makes up the and engineers can proactively and them seamlessly.
facility. When machinery falters, effectively improve plant ROA.
the facility falters; when Aim of Downtime Analysis
machinery fails, the facility fails. Types of Downtime The aim of a Downtime Analysis
As shown in the diagram below, tool is to identify problems and
In a capital-intensive industry such there are many types of trends within a facility to minimize
as mining, where a typical downtimes, ranging from complete the impact of failures for
greenfield site costs over production halt, to machinery that individual machinery, and hence
$450million, the cost of downtime is operating below its specified maximize the efficiency of the
is over $1million per day. In high level, to scheduled stoppages for overall facility.
commodity applications such as routine maintenance. All of these
bottling plants, an hour downtime constitute Downtime to a How it Works
can cost the plant a days manufacturer. All impact Rules, which are sometimes quite
profitability. production and can be improved in complex, are setup in the
some manner, even if that means Downtime Server so that it can
Many of these situations are simply scheduling maintenance monitor events in the control
commonly experienced, and the more efficiently. system. When a rule is met, a
vast majority of them are Downtime is triggered, and as
avoidable, with the appropriate Automated Downtimes are much information as is
monitoring and analysis software. gathered automatically from the electronically available about the
Citect’s Downtime Analysis control system. Manual Downtime is logged to the
module provides producers with Downtimes are entered when there Downtime database. A Downtime
an intuitive tool for monitoring are no electronic means of Notification is sent to selected
and improving plant utilization detecting the failure. users to pro-actively notify them
and efficiency. of the event.
Required Time Standby Time
Required Time Standby Time
Production Time Unscheduled Scheduled
Production Time Downtime Downtime
Unscheduled Unscheduled Scheduled Scheduled
Unscheduled Unscheduled Scheduled Scheduled Standby
Process Equipment Process Equipment Standby
Process Equipment Process Equipment Downtime
Downtime Downtime Downtime Downtime Downtime
Downtime Downtime Downtime Downtime
Healthy facility status. No Downtime Analysis is required.
Planned stoppages or output reductions. More information can help efficiencies through better
scheduling and planning processes. These should be captured for Downtime Analysis.
Unpalnned stoppages or output reductions that significantly affect the facilities ability to delivery high
quality, high throughput product. These are the most costly delays, and those that must be captured for
Authorized users can then open the
Downtime Monitor and complete
the Downtime log for that event.
Powerful filtering and reporting
tools allow managers to analyze
the facility to make better
decisions regarding maintenance,
scheduling or priorities to
maximize the efficiency of the
The Downtime Monitor
The Downtime Monitor is an
interface that allows users to enter
data, adjust parameters and report
on both production and equipment
downtime. It is an intuitive web
interface based on the Plant2Net
classifications from pull down customizable reports outside the
A tree structure allows the facility lists, as well as enter free text Downtime Analysis package if
to be represented graphically, comments and explanations, or required.
making access to equipment fast new manual Downtimes.
and intuitive. A list of Downtimes Key Benefit
is presented in date/time sequential Users can filter Downtimes by The Citect Downtime Analysis
order with powerful filtering and almost any available combination solution allows producers to
summary tools. of parameters to create custom maximize their ROA by helping
reports and views. These filtered improve production and equipment
Downtimes can be selected from views can then be saved for fast efficiency across CitectSCADA,
this list, and users with appropriate access in the future via Favorites. Wonderware InTouch, and
privileges may enter cause Downtime information is stored in Intellution Fix32 and iFix control
locations, causes and a MS SQL Server allowing fully systems.