Micro Stop Log Worksheet for Short Stoppages
Short stops are the loss that rarely appears in a downtime report, because nobody opens a work order for a ten second jam. Together they can cost more output than a few long breakdowns. This log gives operators a simple way to count them by cause and convert the count into lost minutes.
| Time window | Machine | Cause | Seconds per stop (s) | Number of stops | Total seconds | Lost minutes | |
|---|---|---|---|---|---|---|---|
150 | 2.5 | ||||||
120 | 2 | ||||||
198 | 3.3 | ||||||
220 | 3.6667 | ||||||
150 | 2.5 |
Use a consistent threshold for what counts as a micro stop, for example any stop under five minutes that the operator clears without maintenance help. Record counts by tally mark on the line and enter them at the end of each hour.
Capture stops automatically
Optional: a short review of how machine signals could feed a stop log through your MES or ERP.
Optional. The tool and every export work without this. No spam.
How to use the log
Place a printed copy of the cause list at the machine and have the operator make tally marks during the shift. At the end of each hour, enter the time window, the machine, the cause, the average seconds per stop and the number of stops. The sheet multiplies the two to give lost seconds and minutes, and the summary shows the total number of stops and the average length. Review the log with the team at the shift start meeting, and pick the top cause for a root cause session.
Why micro stops matter
In most OEE conventions, stops below a set threshold are not counted as downtime but as a reduction in speed, so they show up in the performance factor. That is why a line can report high availability and still run well below its ideal rate. Logging them separates the true cause of the performance loss from slow running, which needs a different fix such as machine tuning or a revised standard rate.
- Typical threshold: under five minutes, no maintenance call
- Count of stops matters as much as duration
- Frequent stops often point to a small upstream defect
Reading the numbers
Sort the causes by lost minutes and also by count. A cause with many very short stops, like a feed jam, is usually a design or setup issue, while a cause with few long stops may deserve a downtime work order. Compare the average stop length with the cycle time: if the average stop is shorter than a few cycles, automatic recovery or a better sensor may remove it. Track the weekly total to see whether fixes hold.
Common mistakes
The usual failure is a cause list that is too long, so operators pick Other. Keep nine or fewer categories and review Other every week. Another mistake is mixing micro stops into the formal downtime log, which double counts the loss. Decide which log owns each event, write the rule on the sheet, and keep it the same across shifts so comparisons are fair.
Frequently Asked Questions
What counts as a micro stop?
There is no universal rule. Many plants use any stop shorter than about five minutes that the operator clears without a maintenance call. Choose a threshold, write it on the sheet, and apply it consistently so trends are comparable.
Do micro stops affect availability or performance in OEE?
Under the common convention they reduce the performance factor, because the machine was scheduled and technically running. If you count every stop as downtime, they reduce availability instead. Either is valid when applied consistently.
How often should operators enter data?
Tally during the hour and enter once per hour or at least once per half shift. Entering from memory at the end of a shift loses detail and tends to under count small stops.
Can I export this log?
Yes. Export to Excel, CSV or PDF at any time. The calculations run in your browser and nothing is stored on a server.
If your machines already send counts and stop signals to an MES or ERP, we can turn that signal into this log without manual tallying.
Related Tools
OEE Loss Pareto Worksheet
Enter losses by reason code, get minutes per event and totals, and use the list to pick the next improvement target.
MES & Shop FloorRun Rate and Cycle Time Study Worksheet
Time three cycles per part, compare against the standard cycle, and see the speed percentage that drives the OEE performance factor.
MES & Shop FloorSMED Changeover Analysis Worksheet
Break a changeover into steps, mark what can move outside machine stoppage, and total the minutes you recover.
Costing & FinanceOEE Improvement Value Calculator
Convert a planned OEE gain into extra good units and annual contribution margin, so the improvement can be justified.
More MES & Shop Floor tools
See all- Line Balancing Worksheet
- SMED Changeover Reduction Worksheet
- Finite Capacity Scheduling Worksheet
- Production Schedule Template
- Bottleneck Analysis Calculator
- Drum Buffer Rope Buffer Sizing Calculator
- Production Schedule Adherence Calculator
- Production Schedule Release Checklist
- Daily Production Schedule Board Worksheet