What happens in the plant
- Machines are marked as running while producing slower than expected
- Cycle time drift is noticed after output misses the schedule
- Operators and supervisors rely on manual observation to detect slow cycles
- Short speed losses are mixed into general downtime or ignored completely
- Production meetings compare output totals without seeing where pace was lost
Why it matters
Run/no-run status is not enough. A machine can be technically running and still lose capacity through slow cycles, blocked micro-events, or process drift. Without cycle-time context, teams treat output loss as a planning miss instead of an operating condition that could have been corrected earlier.
What teams need to see
Teams need to see current cycle time, target cycle time, run/no-run state, short stops, drift by asset or line, shift comparison, and the time window where pace started to fall.
Decisions this problem affects
- Which asset is running but producing below expected pace?
- Which cycle-time drift should be corrected during the current shift?
- Which short stops are reducing output without appearing as downtime?
- Which line needs supervisor or maintenance attention before the schedule slips?
- Which recurring pace loss should be reviewed in the daily production meeting?