Time Stamp : A key process metric you can collect for free

 

 Data collection is not for free. While an operator is recording data, he/she is not producing. In general variable data such as a speed, temperature, etc. requires some sort of equipment to measure it and therefore it is more expensive to collect than attribute data: Pass/Fail, On-time/Late, etc.

Time is a key variable in any process which can automatically be collected by any PC, Portable, Tablet or Smart Phone, therefore it does not require any additional measuring equipment.

Entering a date or a time manually into a terminal is prone to multiple typing errors which if undetected can distort all subsequent key metrics.

If data is collected on paper and then typed into the system  at a later stage, apart from the waste of this operation, the errors might be difficult to recover.

If we are able to simplify the data recording operation, the operator can report in real time all incidents or data entries, in which case the data collection application can automatically associate a Time Stamp to each piece of data entered:

 

Incident reported

Automatic Time Stamp

Line stopped

21/06/2017  19:40

Line restarted

21/06/2017  20:08

 

The operator just selects the incident from a drop down list and the time stamp is added automatically. 

In the previous example by subtracting the two time stamps you know the line was stopped for 28 minutes. 

The way to register a time stamp with Excel is: 

Current Time Stamp English

Spanish

= NOW()

= AHORA()

 

From a time stamp X you can easily obtain: 

 

English

Spanish

Day of the week

=WEEKDAY(X:2)

=DIASEM(X;2)

Week of the year

=WEEKNUM(X)

=NUM.DE.SEMANA(X)

 

You can also obtain the Shift (Morning, Afternoon, Night) from the hour of the Time Stamp with a formula.

 This data obtained from the time stamp could be very useful during analysis in order to detect significant differences between: 

  • Hours
  • Shifts/ operators
  • Days of the week
  • Weeks
  • Months

 Very often data is still being collected on paper because there are no terminals at the point of use and it would be very costly to install them.

 On the other hand we all use cloud based technologies in our private life: smart phones, tablets and portables sharing data in the cloud, with basically no other cost than the WIFI/ Wideband connection.

 A new approach of BYOD (Bring Your Own Device) is being practiced by some companies which makes data collection almost free by using the employees own smart phone or tablet with the Company WIFI and private cloud.

 In the following example a spread sheet is shared in Google Drive by line operators who report line incidents in real time with their phones and maintenance engineers who report the repair actions the moment they do it also with their phones.  

Equipo Componente
Fecha avería
 
Avería Tipo Fecha actuación prevista
Fecha/ hora actuación
 
Acción de reparación
Contraincendios
 
Tanque
 
25/03/2017 13:02:52
 
Fuga
 
A
 
26/03/2017
25/03/2017 13:19:21
 
Reajustado
 
Pulidora
 
Bomba
 
25/03/2017 13:03:58
 
Fuga
 
A
 
26/03/2017
25/03/2017 13:08:17
 
Limpiado
 
Calibrador
 
Balancín
 
25/03/2017 13:18:04
 
Deformado
 
B
 
1/04/2017
25/03/2017 13:20:33
 
Reemplazado
 
Centrifugadora
 
Cable
 
25/03/2017 13:18:19
 
Fundido
 
A
 
26/03/2017
25/03/2017 13:20:43
 
Acción
 
CIP SKID
 
Chapa
 
25/03/2017 13:18:29
 
Máquina desprogramada
 
C
 
24/04/2017
25/03/2017 13:21:13
 
Reprogramado
 
Cinta transportadora
 
Bombilla
 
25/03/2017 13:18:40
 
Defectuoso
 
C
 
24/04/2017
25/03/2017 13:21:18
 
Reemplazado
 
CIP procesos
 
Engrasador
 
25/03/2017 13:19:05
 
Roto
 
A
 
26/03/2017
25/03/2017 13:21:44
 
Reemplazado
 
Filtro rotativo
 
Chapa
 
25/03/2017 13:19:17
 
Oxidado
 
B
 
1/04/2017
25/03/2017 13:21:54
 
Reemplazado
 
Cinta transportadora
 
Canjilón
 
25/03/2017 13:19:32
 
Salta el fusible
 
B
 
1/04/2017    
Centrifugadora
 
Bomba
 
29/03/2017 17:25:21
 
Fuga
 
A
 
30/03/2017    

 

 

 

 

 

 

 

 

 

 

Operators select the equipment, component, defect and severity with a single touch on each of the pull down lists. The current time stamp is entered automatically and the expected repair date is also calculated automatically from the severity and defect reported date.

 If a repair date is missing and the expected repair date is exceeded cells become red to warn the maintenance engineers. The moment the maintenance engineer enters the repair action the time stamp is also entered automatically. 

Lists of pending repairs are obtained from this table with pivot tables to inform the maintenance engineers of all pending repairs and their due dates and severities.

We can easily extract  reports such as:

  • Average repair times per severity 
  • Correlation between defects and repair actions 
  • Frequency of defective components for each equipment 

CONCLUSIONS: 

  • Paper recording can easily be replaced by widely used devices such as smart phones and tablets which require no operator training
  • Easy  availability of these devices enables reporting in real-time and therefore real-time control of the process
  • This enables the automatic recording of time stamps associated to each piece of data the moment it is entered
  • Data entry is made much more simple and robust by eliminating data entry errors which are difficult and cumbersome to detect and correct at a later stage.