logo

Production Downtime Monitoring System – Real-Time Machine Downtime Tracking & Analysis

The Robato Production Downtime Monitoring System helps factories identify and eliminate machine stoppages, idle time, breakdowns and micro-downtime. It delivers live visibility of downtime events using LED counters, PLC signals, sensors, Andon buttons, tower lights, cloud dashboards and on-prem monitoring.

Production Downtime Monitoring System
Why Downtime Monitoring Matters

Why Downtime Monitoring Matters

Even a small 5-minute stop repeated throughout the shift leads to massive production loss. Most factories face:

  • Frequent micro-stops unnoticed by supervisors
  • No real-time breakdown alerts
  • Manual downtime entries in paper or Excel
  • No way to measure response time
  • Lack of visibility across shifts and machines

Robato's Downtime Monitoring Software solves these issues with automated detection and instant alerting.

Robato Systems

Transform Your Business with Intelligent Automation

Let Robato Systems transform your business with cutting-edge automation solutions. Book a free consultation and see the difference.

How the Downtime Monitoring System Works

From detection to analytics in four steps

Step 1

Downtime Detection

The system detects downtime through:

  • Smart production counters (cycle time analysis)
  • PLC digital inputs (machine running/stopped)
  • Proximity / IR / photoelectric sensors
  • Operator Andon buttons
  • Tower light signal changes
Step 2

Instant Alerting

When downtime occurs, alerts reach:

  • Andon LED boards
  • Smart TV dashboards
  • Supervisors' tablets & mobiles
  • Cloud or on-prem monitoring room
Step 3

Downtime Reason Capture

Operators can enter reasons using:

  • Mobile app
  • HMI or touch panel
  • Web dashboard
  • Andon confirmation buttons
Step 4

Analytics & Reporting

The software generates:

  • Top downtime categories
  • MTTR (Mean Time To Repair)
  • MTBF (Mean Time Between Failures)
  • Shift-wise downtime
  • Machine-wise downtime
  • Line-wise pattern analysis

ROBATO SYSTEMS

"Transform Your Business Today"

Experience cutting-edge production monitoring solutions

"Empowering industries with real-time insights and intelligent automation"

Book a free trial and experience the difference

Key Features of Robato Downtime Monitoring Software

Everything you need for real-time downtime tracking and analysis

Real-time Downtime Detection

Via sensors, counters & PLCs.

  • Automatic detection
  • Cycle time analysis
  • PLC integration

Live Breakdown Alerts

On LED boards & Smart TVs.

  • Instant notifications
  • LED board display
  • Smart TV dashboards

Micro-stop Detection

From cycle-time variation.

  • Pulse timing logic
  • Hidden loss tracking
  • Pattern recognition

Operator Downtime Reason Entry

Via mobile/HMI.

  • Mobile app entry
  • HMI integration
  • Predefined categories

Supervisor Response Tracking

With timestamps.

  • Response time logging
  • Acknowledgement tracking
  • Performance metrics

Escalation Workflow

If issue unresolved.

  • Tiered escalation
  • Timeout triggers
  • Manager alerts

Shift, Line & Machine Dashboards

Complete visibility.

  • Shift analytics
  • Line-wise view
  • Machine status

Cloud & On-Premise Deployment

Flexible options.

  • Cloud SaaS
  • On-prem server
  • Hybrid setup

OEE Calculation Integration

Downtime feeds directly into Availability.

  • Availability tracking
  • Performance metrics
  • Quality integration

API Connectivity

With MES/ERP systems.

  • REST APIs
  • MES integration
  • ERP connectivity

Technical Specifications

Downtime Monitoring Technical Specifications
INPUTS

INPUTS

PLC, counters, sensors, Andon

CONNECTIVITY

CONNECTIVITY

WiFi, Ethernet, MQTT, HTTPs

DEPLOYMENT

DEPLOYMENT

Cloud SaaS / On-Prem

DEVICES

DEVICES

Web, Android, Smart TV

DASHBOARDS

DASHBOARDS

Machine, Line, Plant, Shift

INTEGRATIONS

INTEGRATIONS

OEE, Andon, Production

ROBATO SYSTEMS

"Transform Your Business Today"

Experience cutting-edge production monitoring solutions

"Empowering industries with real-time insights and intelligent automation"

Book a free trial and experience the difference

INDUSTRIES USING DOWNTIME MONITORING

Automotive OEM & Tier-1 Suppliers

Pharmaceutical & Medical Device Manufacturing

Textile Weaving, Knitting & Garment Factories

Electronics & PCB Assembly

Food, Beverage & FMCG Packaging

General Engineering, CNC & Fabrication

Reduce Machine Downtime with Robato Systems

Combine Andon System, OEE Monitoring and Cloud Production Monitoring with the Downtime Monitoring System to achieve complete shop-floor visibility.

Andon System

LED Andon boards, push buttons, tower lights and wireless Andon systems for shop-floor alerts.

OEE Monitoring

Complete OEE tracking with availability, performance and quality metrics. Downtime feeds directly into Availability.

Cloud Production Monitoring

Cloud-based production monitoring for multi-plant visibility and remote access to downtime data.

Frequently Asked Questions

1. What is Production Downtime Monitoring?

2. How does downtime get detected?

3. Can operators enter downtime reasons?

4. Does the system integrate with OEE?

5. Does it support cloud monitoring?

6. Can downtime alerts show on Smart TVs?

7. Can it detect micro-downtime automatically?

8. Can the software integrate with ERP/MES?

9. Can supervisors receive downtime alerts?

10. Does it support multi-machine and multi-line plants?

Loading latest blogs...