Analyze downtime with Pareto and trend charts

Find the few downtime reasons that cost the most, and see whether they are getting better.

The Downtimes report is the root cause analysis tool for production losses. It answers three questions about every stop in your fleet: which reasons cost the most time, how that changes over time, and which machines carry it. The page is at /assets?select=downtimes.

Prerequisites. Machines reporting, see Monitor your fleet on the Assets page. Stops classified, see Classify a downtime event. Every figure on this page is defined in Metrics.

The Downtimes report over the last four weeks. A filter bar across the top shows Machines 22, Shifts, Categories 17, Sort by Date: New to Old, Reset Filters, an Only with Notes toggle, an Actions menu and a Last 4 weeks date button. Below it, the Downtimes by Category Pareto chart ranks nine categories from Mold Wash at 60.76 hours down to Unclassified at 0 hours, with a cumulative percentage line rising to 100 percent. Under that, Downtimes by Time Interval shows four stacked weekly bars, W34 to W37, and Downtimes by Asset shows one stacked bar per machine numbered 214 to 256, each with an hours label.

The Downtimes report. The Pareto orders your reasons by the time they cost.

Read the Pareto chart

Downtimes by Category ranks every downtime reason by total duration, longest first. Each bar is one category, and the line over the bars is the cumulative percentage, so you can read off how many categories make up 80% of the loss.

Start with the leading bar. A plant with 60 hours of Mold Wash and 3.5 hours of Parts in inspection gets more back from a faster mold wash than from a faster inspection.

Is Unclassified your tallest bar? Then the Pareto is ranking the absence of reasons, not the reasons. Put reasons on the stops, or turn on automatic classification for the routine ones.

The Downtimes by Category Pareto chart. Nine bars run left to right in descending order: Mold Wash 60.76 hours, Unplanned maintenance 31.76, Required foreman approval 27.84, Samples sent to postcure 16.50, Lunch Break 10.35, Mold Wash (Sand Blast) 7.73, Parts in inspection 3.50, Breaks - None 0.68 and Unclassified 0.00. A cumulative percentage line climbs from about 40 percent at the first bar to 100 percent at the last.

A Pareto with a clear leader. That bar is where the next improvement is.

Read the interval and asset charts

Two stacked bar charts follow the Pareto. Both split each bar by category, in the Pareto's colors, with a legend on the right. Hover any bar for its exact value.

Downtimes by Time Interval plots downtime per day, week, month, quarter or year, depending on the interval in the date filter. Read it to see whether a reason is trending, seasonal, or responding to a fix. For example, a Mold Wash segment that shrinks week over week after the wash procedure changes is the evidence the change worked.

Downtimes by Asset plots the same downtime per machine, with a duration label on each segment such as 16.73h. Read it to see whether a category is spread across the floor or concentrated on one machine.

Click a category in the legend to hide or show it. Hiding the leading category is the fastest way to see what is underneath it.

Two stacked bar charts with a category legend on the right of each. Downtimes by Time Interval shows four weekly bars labeled W34 (W3 AUG) to W37 (W1 SEP), each split by category color with hour labels such as 26.01h for Mold Wash. Downtimes by Asset shows one bar per machine, numbered 214 to 256, split by the same colors, with labels such as 16.73h on machine 226 and 17.78h on machine 244.

The same downtime split by interval and by machine.

Filter the report

The filters sit across the top of the page, or behind the Filters button on a phone. Every filter is written into the address bar, so the URL is the report: copy it and it opens in the same state for anyone with access.

The date filter picks both a window and an interval, the grouping the by-interval chart uses. Choose Daily, Weekly, Monthly, Quarterly or Yearly, then a rolling preset such as Last 7 days, or a custom range. A rolling preset stays rolling: a link to Last 7 days shows the last seven days on the day it is opened.

Filters reference

Filter	Values	Applies to
Date	An interval (Daily, Weekly, Monthly, Quarterly, Yearly), then a rolling preset for that interval or a custom range	Every chart and the table. The interval also sets the grouping of Downtimes by Time Interval
Machines	Whole departments, or individual machines inside them	Every chart and the table
Shifts	One or more of your organization's shifts, multi-select	Every chart and the table. Only stops inside the selected shifts count
Shift islands	On or off, at the top of the Shifts popover. Off by default	Every chart and the table. On, a shift that crosses midnight reports entirely on the day it began
Categories	Individual downtime categories, plus Unclassified	Every chart and the table
Severity	A group heading inside Categories: Unclassified, None, Low, Medium, High, each with a count. Ticking a heading selects every category of that severity	Every chart and the table
Sort	Date: New to Old, Date: Old to New, Duration: High to Low, Duration: Low to High	The table only
Only with Notes	On or off	The table only. Hides stops that carry no operator note

Severity is a rank each category carries, set when the category is created, see Manage downtime categories. Reset Filters clears every filter except the date.

Turn on Shift islands before you read a night shift's downtime. Off, the hours a shift works after midnight are charged to the next day, so a Monday-to-Friday night shift puts downtime on Saturday, a day it never ran. This report and the Advanced Report are the only two places the toggle exists, see Where the overnight hours land.

The right of the Downtimes by Time Interval chart, filtered to the Evening Shift, which runs 5 PM to 1 AM Monday through Friday, with Shift islands off. Three columns stand over the day labels Thu Sep 24, Fri Sep 25 and Sat Sep 26. The Thursday and Friday columns are tall, each a red Unclassified block over a blue Entire Shift Down block labeled 12h and 28h. The Saturday column is a stub, labeled 3.34h and 10h.

The last three days of the week, Shift islands off. Saturday carries ten hours of Entire Shift Down from Friday night, on a day the Evening Shift never runs.

Two filters answer two different questions:

Filter to Only with Notes when you are building a maintenance case. The notes are what a technician needs.
Filter to Unclassified when you are checking whether operators are keeping up. A growing unclassified share means the habit is slipping, not that the plant is running better.

The Downtimes report filter bar with the Categories popover open. The bar shows Machines 22, Shifts, Categories 14, Sort by Date: New to Old, Reset Filters, an Only with Notes toggle, an Actions menu and a Last 4 weeks button. The popover has a Search categories box, then a LOW heading with its own checkbox and 12 categories such as Short Downtimes, Shift change and Machine setup, then a MEDIUM heading with 21 categories such as No job and Broken tool, and Clear and Apply buttons at the bottom.

Every filter on the report. The severity headings inside Categories select every reason of that severity at once.

Read the detail table

Below the charts, a table lists each stop matching the filters, 25 to a page.

Column	Shows
Machine	Photo, name and identifier, with the stop's start and end times
Duration	How long the stop lasted
Category	The downtime reason, or blank if unclassified
Categorized By	The person who classified it, or IoTFlows AI for stops an automatic rule classified
Note	The operator's note, if one was added
Severity	The category's severity as a colored badge: None, Low, Medium or High

The table covers stops that overlap your selected dates and shifts, up to the first 1,000 stops or the first three months. A stop that began before the window, or falls past that limit, is not listed. Narrow the date range if you need every row.

Every time on this page is in the organization's time zone, not yours, see Shifts and time zone.

The detail table. Filtering to only-with-notes builds a maintenance case quickly.

Export the report

The Actions menu at the right of the filter bar downloads the report in two forms, both using the filters you have set. What each export carries is listed in Available exports.

Download a CSV

Set the filters.
Open Actions.
Click Download as CSV.

The file Downtime Classification Data.csv carries one row per stop: machine identifier and name, start and end timestamps, duration, category and note. Choose CSV when you want the rows themselves, to pivot in a spreadsheet.

Download a PDF

Set the filters.
Open Actions.
Click Download as PDF.
Wait for Generating PDF report… this may take a few seconds. to become PDF report generated successfully.

The file Downtime_Report_<from>_to_<to>.pdf is rendered from the report as you see it, charts included. Choose PDF when the reader needs the picture rather than the rows, for example a weekly review with a plant manager.

You do not need to export to get the report to other people. Share emails the current view to members of your organization, and Schedule sends it on a cadence, see Email a report and schedule it to repeat.

Export errors

Message	Means
Failed to download CSV. Please try again.	The browser could not build the file. Reload the page and retry once the table has loaded
Something went wrong generating the PDF.	The PDF service could not render the report. Retry; if it repeats, narrow the date range

Classify as it happens

The report is only as honest as its classifications. Two habits keep it useful.

Turn on automatic classification for short stops, start and end of shift, and scheduled breaks, see Classify downtime automatically.

Put a tablet at each machine, assigned to that machine, so operators classify a stop as it happens and the note is fresh, see Set up a dedicated operator station.