DTRCA transforms paper-based downtime logs into real-time digital tracking—capturing events as they happen, enabling instant Pareto analysis, 5-Why investigations, and corrective action management for continuous improvement.
From real-time event logging to root cause investigation, DTRCA provides the digital infrastructure for continuous improvement.
Real-time capture of start/end times, equipment ID, category, reason codes, responders, and corrective actions taken.
Daily/weekly compilation with total downtime by equipment, Pareto analysis, target comparison, and trend charts.
Automatic capture of fault codes, descriptions, axis involved, program running, and recovery actions for robotic systems.
Documentation of false reject counts, reason codes, sample images, and recipe adjustments for vision systems.
Automatic capture of alarm history from HMI screens—no more manual transcription from control panels.
Instant breakdown documentation triggering emergency repair workflows with automatic notification routing.
Structured root cause investigation templates guiding teams through systematic problem decomposition.
Digital Ishikawa cause-and-effect templates for comprehensive analysis across Man, Machine, Method, Material.
Formal documentation of systemic issue resolution with action tracking, verification, and effectiveness review.
DTRCA uses a consistent categorization system enabling meaningful Pareto analysis and targeted improvement initiatives.
Equipment failures, worn components, jammed mechanisms, broken tooling, conveyor faults, and physical damage.
Power failures, drive faults, sensor malfunctions, wiring issues, communication losses, and control system errors.
Out-of-spec production, vision rejects, measurement failures, rework requirements, and process adjustments.
Raw material shortages, component supply issues, incorrect materials, material defects, and handling problems.
Product changeovers, tooling changes, recipe switches, setup time, and first-article validation delays.
Scheduled maintenance, training, meetings, breaks, no-demand periods, and miscellaneous stoppages.
DTRCA provides digital templates for proven root cause analysis methodologies to eliminate recurring failures.
Iterative questioning technique drilling down from symptom to root cause through five levels of "why" questions.
Visual cause-and-effect analysis organizing potential causes into standard categories for comprehensive investigation.
Automatic ranking of downtime causes by frequency and duration to focus improvement efforts on the vital few.
Formal tracking of actions from identification through implementation with verification and effectiveness review.
DTRCA digitizes the manual forms your team uses daily, ensuring complete traceability and instant analysis.
Real-time digital capture replacing paper logs with automatic duration calculation and instant categorization.
Structured digital template guiding teams through systematic root cause decomposition for recurring failures.
Structured review of previous day's downtime events with action assignment and follow-up tracking.
DTRCA eliminates hours of manual data entry, report compilation, and investigation paperwork—freeing your team for improvement work.
| Activity | Hours/Day | Days/Year | Annual Hours | FTE Equivalent |
|---|---|---|---|---|
| Real-time downtime logging | 2-4 | 250 | 500-1,000 | 0.25-0.5 |
| Daily downtime data compilation | 1-2 | 250 | 250-500 | 0.12-0.25 |
| Weekly/monthly report creation | 2-4 | 52 | 104-208 | 0.05-0.1 |
| Root cause analysis execution | 2-4 | 100 | 200-400 | 0.1-0.2 |
| Corrective action documentation | 1-2 | 100 | 100-200 | 0.05-0.1 |
| Management review preparation | 2-4 | 52 | 104-208 | 0.05-0.1 |
| Total Potential Savings | — | — | 1,258-2,516 | 0.62-1.25 |
Join manufacturers achieving 40% fewer repeat failures with real-time tracking, automated Pareto analysis, and structured root cause investigation.