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Manually tracking cycle times with a stopwatch and spreadsheets? Pinpoint bottlenecks and increase operational throughput with automatic cycle time tracking powered by Caddis Systems.
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Cycle time tracking is the use of technology, such as sensors and software, to automatically capture the precise time it takes to complete a single step of a manufacturing process, or the entire process from start to finish.
Unlike manual tracking, which is often prone to human error and inconsistency, Caddis systems provide a continuous stream of accurate data. This allows for a granular understanding of every phase of production, from the moment a machine begins working on a part until the process is complete. By eliminating guesswork, you gain a true measure of your operational performance.
To effectively improve efficiency, it's crucial to understand the different elements that constitute the total cycle time.
Automatic tracking systems can help dissect and analyze each of these components:
Process Time: This is the value-added time during which a machine is actively working on a part. It's the core of the manufacturing process where raw materials are transformed.
Move Time: This non-value-added time is the duration it takes to transport a part or materials from one workstation or process to the next.
Inspection Time: This is the time spent on quality control checks, whether they are performed manually by an operator or through an automated inspection system.
Queue Time: Also known as wait time, this is the non-productive period a part spends waiting for the next process to become available. This is often a significant source of hidden inefficiency.
The formula for calculating total cycle time is:
Total Cycle Time = Process Time + Move Time + Inspection Time + Queue Time
By tracking and analyzing these individual components, a business can pinpoint bottlenecks and non-value-added activities, leading to more targeted and effective process improvements.
The shift from manual to automatic cycle time tracking can have a transform your manufacturing operations and overall profitability. Here's why it's a critical investment for any modern manufacturer:
Unparalleled Accuracy: Automatic systems eliminate the inaccuracies and inconsistencies of manual data collection, providing a reliable foundation for decision-making.
Real-Time Visibility: Gain an up-to-the-second understanding of your production flow. Instantly identify when a process is taking longer than expected and address issues as they happen, not after the fact.
Increased Throughput and OEE: By pinpointing and reducing non-value-added time (like queue and move times), you can significantly increase your production output and boost your Overall Equipment Effectiveness (OEE).
Data-Driven Process Improvement: With precise data, you can identify the true bottlenecks in your production line and focus your improvement efforts where they will have the greatest impact.
Accurate Costing and Quoting: A clear understanding of your cycle times allows for more precise product costing and more competitive and reliable customer quotes.
Enhanced Production Scheduling: Armed with accurate cycle time data, you can create more realistic and achievable production schedules, leading to improved on-time delivery rates and customer satisfaction.
Caddis Systems provides your team with real-time machine insights to track cycle time, utilzation, downtime, OEE, and more.
Monitor machine health and performance in real time through continuous tracking of critical metrics — including downtime, utilization, OEE, cycle time, changeover time, and condition data.
Log and timestamp machine downtime events to generate comprehensive reports. Identify the root causes of downtime and develop strategies to minimize disruptions and enhance productivity.
Schedule maintenance tasks proactively to minimize unexpected downtime and extend the lifespan of your machines.
Receive instant notifications via text or email based on live machine data. Act swiftly to avert prolonged downtime, reduce repair expenses, and ensure seamless operations.
Most machine monitoring tools hand you a dashboard and walk away. Caddis comes loaded with battle-tested playbooks — built from years on our own factory floor — so your team knows what to do with the data from day one
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Shift from reactive to proactive. Schedule maintenance by actual runtime and cycle counts — not guesswork — so you catch problems before they become expensive emergencies.
Pinpoint your top three downtime causes in the first week. Then systematically eliminate them using a proven root-cause framework your whole team can follow — no analyst required.
Uncover hidden capacity that's already sitting in your shop. Identify idle patterns by shift, operator, and machine — then close the gap with targeted scheduling adjustments.
Move your OEE score from a vanity metric to an action plan. Track availability, performance, and quality together — then follow a weekly cadence to drive measurable gains each month.
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Caddis devices can be installed same day with no disruptions. No I.T. Team required.
Plug Caddis devices into your machines — works with virtually any legacy or modern equipment. Most shops are up and running in under 2 hours.
View real-time machine insights to benchmark performance and identify downtime reasons.
Use pre-built reports, dashboards and expert guides to make reduce unplanned downtime and improve productivity.
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See how Caddis can provide real-time machine insights and expert guides to help improve your plant operations on Day 1.
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