Measuring is easy; explaining is not

Connecting a machine and counting stops takes days. Knowing why it stopped needs people: the operator is usually the only one who knows.

Design the code tree with operators

• Keep it short: three levels, around 30–40 codes in total.

• Make coding fast: two taps at the machine, not a form at the end of the shift.

• Code only stops above a threshold (for example 2 minutes) to keep the effort reasonable.

Measure the baseline honestly

The first weeks of automatic data are usually lower than the numbers previously reported. That is not deterioration; it is the first accurate measurement. Agree in advance that this baseline is the starting point.

Act on the top losses

Review the top three losses every week, assign an owner and track them. Without this routine, the dashboard becomes decoration.