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Analyze causes for Downtime and Rejects....then eliminate them.

Pareto Chart like the one below sorted by machine,product, operator, shift, etc., to help you focus on the most critical causes of downtime; then put in place appropriate programs to eliminate or minimize the causes. A Pareto chart of Rejects can be prepared in a similar fashion.

Calendar-scheduled Preventive Maintenance is inefficient and ineffective; replaceit with maintenance scheduling based on run time and cycle count data.

Usage-based PM minimizes job interruptions to unplanned maintenance . The PM Module tracks the number of cycles andrun time for each machine, main tool, or sub tool/component--data that is automatically collected by all models of MDT. Both number of cycles and run time have alarms/thresholds (total hours or total cycles) to trigger maintenance operations.

A Master Tool can be defined either as the machine the MDT is attached to, or it can be a group of components: youcould define a combination of printing plates and die cutters as a Master Tool. Sub Tools are components of the MasterTools. Sub Tools are typically used on more than one Master Tool---for example, a die may use several punches depending on the job being run. The punches may also be shared by more than one die and may be set up so that their cycles and run time hours are also tracked. Only Master Tools may have associated Sub Tools

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The Tool Life and Top PMs lists showTools or Scheduled PMs that are currently due (that is, having reached 95% of its run time or cycle count). Selecting an item in either list allows the Main PM Window to update the selected PM. Color is used to graphi- cally show which hourly or cycle count limit has been exceeded. The PM module provides for loggingchanges and maintenance performed so that entries may be reviewed and analyzed to improve maintenance processes. The system keeps a record of who enters changes and performs maintenance, because all users must log in at a system PC.

Machine usage data (run time and cycle counts) can be automatically exported to any EAM/CMMS systemto eliminate the errors and non-productive labor associated with manual “meter” reading. MDT’s collect Down Reasons and Reject counts -- automatically through direct machine connection and also byOperator keypad input. Depending on the model of MDT, you can track up to 40 Downtime Reasons. When the machine is “down”, the MDT keeps track of the time and prompts the Operator to refer to a Down Reason menu onthe MDT and enter a Reason number. You can prepare a