Analytics & Metrics Documentation
A comprehensive guide for management on reading and interpreting dashboard data.
1. Availability & Downtime Metrics
These metrics help identify how much time is being lost to machine stoppages and the frequency of those stops.
Machine Utilization Rate (%)
(Total Run Time / Total Shift Time) × 100
Represents the percentage of the available shift time that the machine was actively running and producing.
How to read it: A high utilization rate (e.g., >85%) indicates optimal planning and minimal downtime. A low rate signals excessive idle or fault time that requires investigation.
Downtime Ratio (%)
(Total Stop Time / Total Shift Time) × 100
The exact inverse of the Utilization Rate, showing the percentage of time lost during the shift.
How to read it: Consistently high downtime ratios indicate systemic issues, such as poor maintenance, raw material shortages, or operator delays.
MTTR (Mean Time To Recover)
Total Stop Time / Total Number of Stop Events
The average duration of a single stop event. It measures how quickly the team responds to and resolves a stoppage.
How to read it: If MTTR is high, operators/mechanics are taking too long to fix issues. Focus on better maintenance training, quicker alert systems, or spare parts availability.
MTBF (Mean Time Between Failures/Stops)
Total Run Time / Total Number of Stop Events
The average uninterrupted running time between stops. It indicates machine stability.
How to read it: A low MTBF means the machine is stopping very frequently (micro-stops). This usually points to minor material jams or operator inattention rather than major breakdowns.
2. Production & Performance Metrics
These metrics relate operational time back to actual manufacturing output, highlighting efficiency and opportunity costs.
UPH (Units Per Hour)
Total Count / (Total Run Time in Hours)
The actual production speed when the machine is in the "Running" state. It ignores downtime.
How to read it: If the machine has high Utilization but low UPH, the machine is running too slowly (Speed Loss). Operators might be running it below optimal RPM.
Effective UPH
Total Count / (Total Shift Time in Hours)
The "real-world" production speed, factoring in all downtime and interruptions.
How to read it: This metric determines if you will meet your daily quota. Comparing normal UPH to Effective UPH highlights exactly how much output is lost due to stops.
Opportunity Cost (Lost Units)
(Total Stop Time in Minutes) × (Average Units Produced Per Minute)
An estimate of how many extra units could have been produced if the machine had not stopped.
How to read it: This is a powerful metric for ROI calculations. It translates lost time into lost products, helping management justify expenses for new parts or additional maintenance staff.