Stop Finder Configuration

WHAT THIS IS

• Stop Finder Configuration is a set of settings that determines when Factbird considers a production line to be stopped. These settings define the minimum duration of a stop, the conditions under which a sensor is considered stopped, and which stops require operator registration.
• Factbird provides default values, but the configuration can be adjusted to match the behavior of a specific production line.

WHY IT MATTERS

• Stop Finder Configuration directly affects downtime tracking, speed loss calculations, micro-stop detection, and OEE reporting.
• Incorrect settings can cause short interruptions to be classified incorrectly or lead to inaccurate downtime durations.
• Proper configuration helps ensure operators focus on the most relevant production losses.

WHEN YOU WOULD USE THIS

• Use this when:
  • Reviewing the accuracy of downtime and OEE data.
  • Adjusting stop detection behavior for a specific production line or product.
  • Evaluating the balance between speed loss, micro-stops, and registered stops.
  • Working with production lines that have long or variable cycle times.

HOW IT WORKS

• The Stop Finder continuously evaluates sensor data to determine whether production is running or stopped.
• The Minimum Stop Duration defines how long a production interruption must last before it is classified as a stop. Shorter interruptions are treated as speed loss.
• The Value Threshold defines the sensor value below which the line is considered stopped.
• The Stop Registration Threshold determines which detected stops are shown to operators for stop-cause registration. Stops below this threshold are classified as micro-stops.
• For lines with long cycle times, Cycle Time Subtraction can improve accuracy by removing the expected production cycle time before evaluating stop duration.
  
  
  
  
  

• Example: If you have a Factbird on a line that counts 1 item every 5 minutes, and you have a 1 minute stop on the line, this will show up as a 6 minute stop in Factbird. With “Subtract Cycle Time” enabled, the first 5 minutes will be subtracted, so you’ll see a 1 minute stop
   

  Note: That enabling cycle time subtraction on lines with high cycle time most likely requires reducing your stop registration threshold and minimum stop duration as these durations no longer have to take into account the cycle time of the line

   

KEY TERMS / COMPONENTS

• Minimum Stop Duration:
  • The shortest interruption that Factbird will classify as a stop. Interruptions below this duration are treated as speed loss.
     
• Value Threshold:
  • The sensor value at which Factbird considers the production line stopped.
     
• Stop Registration Threshold:
  • The minimum stop duration required before operators are prompted to register a stop cause.
     
• Micro-stop:
  • A stop that is longer than the Minimum Stop Duration but shorter than the Stop Registration Threshold.
     
• Speed Loss:
  • Reduced production performance caused by short interruptions or slower-than-expected operation.
     
• Cycle Time Subtraction:
  • A feature that subtracts the expected cycle time before evaluating stop duration, improving accuracy on lines with long cycle times.
     
• Stop Finder:
  • The Factbird system component responsible for detecting and classifying production stops.

COMMON MISUNDERSTANDINGS

• Lowering the Minimum Stop Duration does not always improve accuracy. It should never be set below the product's cycle time. This by default is set to 10 seconds 
• Increasing the Value Threshold does not simply make stop detection more sensitive. It can also affect OEE calculations because pieces produced during the detected stop are not considered in stop duration calculations.
• Micro-stops are not ignored by Factbird. They are tracked separately from registered stops. If micro-stops are a significant contributor to downtime, you can lower the stop registration threshold and hence ask operators to register more stops. You can also consider enabling automatic stop registration using PLC tags see: Register stop causes using PLC tags
• Cycle Time Subtraction does not change production speed. It changes how stop durations are calculated for stop detection.