Downtime 

Definition

Time in which a resource is not productive.

In the standard system, the most commonly used downtimes are predefined. Along with these predefined downtimes, you can also define your own user-specific downtimes.

Use

In industries with production, resource efficiency and resource utilization are very important figures. Elementary indicators for them are the different downtimes. In the SAP System, downtimes can be entered and evaluated in SAP BW (SAP Business Information Warehouse) or LIS (Logistics Information System).

Structure

Downtimes are assigned when you enter downtime elements. Each downtime element describes a predefined downtime category. Default times are available for some of the downtime elements to make it easier to enter them. They are calculated from data that comes from different components in the SAP System. Default times are available, for example, for vacation, non-productive days, breaks, shift changes, setup, teardown, repair and maintenance times.

The downtime elements are grouped in categories that show the same characteristics or a business mutuality. The categories are predefined. You cannot create your own categories. You also cannot change the assignment of predefined downtime elements to the categories.

Downtime Categories

Production-related downtime

All downtimes in production that can be scheduled as operations or phases, such as setup or teardown time.

Nonproduction-related downtime

Machine-related malfunctions as well as malfunctions that are not machine-related, such as a decrease in capacity, environment problems, or a shortage of material or labor.

Order-related downtime

The duration of a whole order that occupies the resource for purposes other than production, such as experiments at a resource or the external use of a resource .

Work center-related downtime

For example, maintenance, breaks, shift changes.

Plant-related downtime

For example, vacation or holidays

Other downtime

Other downtimes

 

Integration

The default values for the duration of downtimes are calculated by the SAP system. They come from the resouce master data, the order and from Plant Maintenance (PM). The following table describes how and from where the default values are determined.

Default values for downtimes

Source

Vacation / holidays

Factory calendar

Non-productive days

Available capacity

Breaks

Resource/work center

Shift change

Resource/work center

Setup

Recipe/routing

Teardown

Recipe/routing

Maintenance time

Plant Maintenance (PM).

 

Function Modules for Downtime Default Values

The following table contains a list of the function modules available for determining default values in the standard system.

Function Module

Description

Collect_Break_DT

Reads the break time defined in the standard available capacity in the resource master data (Resource Capacity: Header screen)

Collect_Maintenance_DT

Maintenance time

Collect_Service_DT

Repair

Collect_Shift_DT

Time between shift finish and shift start (several are possible on one day). The shifts are defined in the resource master data.

Collect_Holiday_DT

Reads the days from the factory calendar that are defined as non-working days.

Collect_Stopage_DT

The data for the non-productive time comes from plant maintenance. Here each resource is assigned an internal number for a functional location. The function module reads the data from the downtime statistics table for each functional location and each day.

Collect_Setup_DT

After order confirmation, the setup and teardown time is written in the order. This function module reads the setup times from the manufacturing orders (production or process orders).

Collect_Tear_Down_DT

After order confirmation, the setup and teardown time is written in the order. This function module reads the teardown times from the manufacturing orders (production or process orders).

 

You can also define your own downtimes and display a report of all downtimes that exist in your enterprise. You can use a user-exit to determine the default values.

 

The downtime data is sent both to SAP BW as well as to LIS where it can be evaluated according to how it is categorized.