Manufacturing downtime tracking
Factbird records every stop automatically, operators add the cause, and you see exactly where production time goes by line, shift, and batch. Installs in under an hour per line without stopping production.
"Instead of reacting to breakdowns, we can focus on recurring stop causes and prioritize preventive actions. Data is no longer something we look at afterwards. It is embedded in how we operate every day."
Why manual downtime tracking falls short
Most factories log downtime by hand or not at all. Short stops never make it onto the sheet, and the reasons that do get written down are hard to compare:
- Downtime often goes unnoticed
- Data collection is inconsistent and prone to errors
- Reporting lags behind actual performance by hours or days
- Root causes of downtime remain unclear
- Resources get wasted chasing symptoms instead of solving problems
The result is reactive management, missed efficiency gains, and the same stops coming back week after week.
How downtime tracking helps you reduce downtime
Factbird makes it easy to capture every stop, see its cause, and identify where to focus your improvement efforts. Real-time visibility replaces guesswork with facts, so you can act on downtime as it happens instead of discovering it days later.
Track every type of downtime
Planned or unplanned, every stop gets a category. Use a standard structure across lines and sites, or define your own.
Unplanned downtime
Breakdowns, jams, and missing material. The stops that hurt most and are hardest to see on paper.
Maintenance
Planned and corrective maintenance, so you can see what it costs in production time.
Cleaning
Scheduled cleaning and sanitation, tracked separately from unplanned stops.
Starting production
Start-ups and changeovers between products or batches.
Staff related
Breaks, meetings, and missing operators.
Machines
Stops traced to a specific machine on the line.
Factbird’s downtime tracking software
Capture every stop without disrupting your operations. Factbird retrofits onto the equipment you already have.
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Non-intrusive solution
An end-to-end solution that is retrofitted to seamlessly integrate with existing infrastructure.
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Scalable solution
Unlimited users and infinite digital and analog data inputs.
Secure data
Advanced encryption and secure network communication ensure maximum protection of your data.
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Fast installation
Installation can be done in under 1 hour, while production continues uninterrupted.
Productivity improvements in the first 90 days with Factbird
Benchmarks are drawn from 372 production lines.
Downtime tracking features that drive results
Leading manufacturers have been using Factbird since 2016 to reduce downtime and increase productivity.
Ease the reporting burden
Simplify the process for your team on the factory floor. Cut out tedious manual tasks and help operators easily communicate stop causes. Rich data helps you pinpoint root causes and improve your uptime.
Spotlight on downtime causes
Visualize the causes for downtime on a Pareto chart and understand both productivity impact and frequency.
Deep dive into the biggest issues and identify patterns that will help you problem-solve and continuously improve.
See what stopped your line
Quickly identify the root cause of stops by clicking on the data point and watching the video. You get footage of the line at the exact moment it stopped, so you can diagnose and fix problems straight away.
Empower your team with real-time support
Operators use Andon to signal urgent needs, and technicians prioritize tickets by urgency. Notifications go out by SMS or email, follow your escalation roles, and match your shift schedules.
Stay ahead of downtime with cycle based maintenance
Sync maintenance scheduling with actual production cycles, not just calendar time. Schedule repeating maintenance tasks dynamically based on machine use and get the most out of your machinery.
Frequently Asked Questions
What is manufacturing downtime tracking?
Manufacturing downtime tracking records when a machine or line stops, for how long, and why. Automated tracking captures every stop as it happens, including short stops that manual logs miss, and adds the cause so you can see which problems cost the most production time.
How does Factbird track downtime?
Factbird collects data through plug-and-play IIoT edge devices, PLC integrations, and software connections like Kepware, tracking production counts and downtime events as they happen. Operators log and categorize stops through Operator View, which keeps the data clean and consistent without adding friction to the shift.
Can Factbird work with older equipment?
Yes. Factbird® DUO and other Factbird edge devices retrofit onto legacy machinery without expensive upgrades or infrastructure overhauls.
Can we see what caused a stop?
Yes. With video process analysis, you click on a stop in the data and watch footage of the line at that exact moment, or just before it, to find the root cause.
How quickly will we see results?
Most customers see actionable insights within hours of installation. Based on customer data, manufacturers using Factbird improved OEE by an average of 9 points and productivity by 19% within the first 90 days.
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