Do your machines count parts and log downtime by themselves?

A simple sensor or a link to the machine records every part made and every stop. Operators just tap a reason, and nobody fills in a count sheet.

How to automate it

How to automate “fill in paper production logs and counts”

Here are 2 ways to spend less time on this, best first. Each comes with steps you can follow today.

20 min

typically, every day

60%

of the time can be automated

Some setup

to set up

Fix 1 of 2

AutomationBest fix

Let the machines record counts, downtime and OEE themselves

Simple machine monitoring (a sensor or a link to the machine controller) counts parts and logs stops automatically. Operators only pick a reason for each stop on a tablet, and the KPI report is always up to date.

Typically saves about 70% of the time8 h to set up

1Pick one bottleneck line or machine to start.
2Trial a machine monitoring tool (Vorne XL, MachineMetrics, Evocon, Guidewheel, or your MES if you have one).
3Set up a short list of downtime reasons operators can tap.
4Replace the paper count sheet on that line, then roll out to the rest.

Tools: Vorne XL · MachineMetrics · Evocon · Guidewheel · Your MES

Fix 2 of 2

Software feature

Swap paper checksheets for tablet forms that feed the system directly

Digital forms on a tablet at the line fill in date, shift, line and operator for you, check values against limits, and send data straight where it is needed. Nobody types the clipboard in later.

Typically saves about 60% of the time4 h to set up

1List the paper forms filled in most each shift.
2Rebuild the top three as digital forms in a connected-worker app or Power Apps.
3Mount a tablet at the station or let people use a shared device.
4Set alerts for out-of-limit values and stop printing the paper version.

Tools: Tulip, Poka, Augmentir, SafetyCulture or Microsoft Power Apps

Quick wins

Have you tried…

Do your machines count parts and log downtime by themselves?: A simple sensor or a link to the machine records every part made and every stop. Operators just tap a reason, and nobody fills in a count sheet.

Who does this task

Roles in our library that list this as one of their common tasks. Each guide covers the rest of that role’s week.

Machine operator / line worker

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