What happens in the plant
- Downtime events are captured without clear recovery priority
- Micro-stops accumulate without recurrence tracking
- Speed loss is treated as normal variation instead of structured loss
- Stop reasons differ by team, reducing comparability across shifts
- Loss ownership is unclear when multiple functions are involved
Why it matters
The cost is not only the lost minutes. Repeated stop, speed, and quality loss patterns stay unresolved, so the same constraints return in the next shift and daily production meetings debate totals instead of assigning recovery action.
What teams need to see
Teams need loss visibility by line, asset, shift, reason, duration, recurrence, owner, and recovery status while production is still running.
Decisions this problem affects
- Which loss should be recovered first this shift?
- Which stop reason repeats across shifts and needs root-cause action?
- Which asset needs immediate intervention to recover output?
- Which owner should take the next recovery action?
- Which unresolved loss should be escalated before handover?