Operating time refers to the actual duration a machine, system, or production line operates and produces output. In manufacturing, operating time is a critical key performance indicator (KPI) that directly impacts productivity, efficiency, and overall equipment effectiveness (OEE).
Operating Time Definition
Operating time is the net productive time when equipment actively performs its intended function. Unlike availability time, which includes standby periods, operating time only counts actual production or operational hours.
In Manufacturing Execution Systems (MES) and production data collection environments, operating time serves as a fundamental metric for production planning and optimization.
Operating Time vs. Related Metrics
Understanding the distinction between operating time and similar metrics is crucial:
- Available Time: Total time equipment is theoretically ready for operation
- Running Time: Time equipment is powered on (may include idle periods)
- Productive Time: Time spent creating value-added output
Factors Affecting Operating Time
Positive Factors
- Preventive Maintenance: Scheduled maintenance reduces unplanned downtime
- Equipment Quality: High-quality machines experience fewer failures
- Process Optimization: Efficient workflows minimize changeover times
- Digital Monitoring: IoT sensors enable early problem detection
Negative Factors
- Unplanned Downtime: Equipment failures and technical issues
- Setup Times: Tool changes and production changeovers
- Quality Issues: Rework and defect handling
- Material Shortages: Missing components or raw materials
How to Calculate Operating Time
The operating time formula is:
Operating Time Rate (%) = (Actual Operating Time / Planned Operating Time) × 100
Example:
- Planned operating time: 480 minutes (8-hour shift)
- Downtime: 60 minutes
- Operating time: 420 minutes
- Operating time rate: (420 / 480) × 100 = 87.5%
Operating Time in OEE Calculation
Operating time is integral to Overall Equipment Effectiveness (OEE):
OEE = Availability × Performance × Quality
Operating time directly influences the availability component: Availability = Operating Time / Planned Operating Time
Strategies to Optimize Operating Time
1. Predictive Maintenance
Implement IoT sensors and AI algorithms to predict maintenance needs before failures occur.
2. Digital Solutions
- MES Systems: Real-time production data capture
- Cloud-native MES: Scalable monitoring and control
- BDE Systems: Automated operating time tracking
3. Process Improvement
- Reduce changeover times using SMED methodology
- Standardize operating procedures
- Optimize production scheduling
4. Workforce Training
Train operators in troubleshooting and basic maintenance to minimize response times.
Operating Time in Industry 4.0
Modern manufacturing leverages operating time data through:
- Real-time Dashboards: Instant visibility into production status
- Data Analytics: Identify optimization opportunities
- Automated Responses: Smart systems that adjust to disruptions
Best Practices for Operating Time Management
- Implement Continuous Monitoring: Use MES and BDE systems for real-time tracking
- Establish Baselines: Define target operating time rates for each production line
- Regular Analysis: Review operating time data to identify improvement opportunities
- Standardize Processes: Create consistent procedures to minimize variability
Conclusion
Operating time is a fundamental manufacturing KPI that directly impacts productivity and profitability. By implementing modern MES systems, cloud-native solutions, and data-driven optimization strategies, manufacturers can maximize operating time and achieve competitive advantages in today's demanding market environment.