Leap Sensors are specially designed to easily adapt to your specific needs. If this isn’t exactly what you need, please contact us.
Equipment Utilization and Downtime Monitoring Sensor Specifications
Accurate Machine Downtime Monitoring
This system functions as a comprehensive equipment utilization and downtime tracking solution for availability analysis and continuous improvement efforts.
- Sensor integrates with a current switch, amp clamp, or other on/off contact to detect true/false or open/close conditions.
- Each transition between active and inactive states is time-stamped and stored.
Machine Cycle & Stop Count Monitoring
The sensor uses a split-core amp clamp or a proximity sensor to function as a machine cycle counter. Ideal for supporting structured machine downtime tracking and reliable production reporting.
- When using a split-core amp clamp, the counter increments each time current exceeds the defined “on” threshold.
- Proximity sensors may also be used to detect open/close mechanical movement.
- Configurable debounce settings prevent false multiple counts caused by signal flicker
Downtime Tracking & Reduction Capabilities
Detailed level of visibility helps operations teams identify recurring causes and implement strategies to reduce equipment downtime and minimize downtime across production lines.
- Tracks every downtime event individually
- Measures total uptime and downtime since last reset
- Maintains a running total for machine availability calculations
- Stores historical data for long-term downtime analysis
Automated Downtime Alerts
When downtime exceeds user-defined thresholds, the system can trigger:
- Text alerts
- Email notifications
- Telephone alerts
Real-time notifications support faster response times and proactive downtime prevention, helping reduce lost production hours.
OEE & Manufacturing KPI Monitoring
For operations focused on continuous improvement, the system tracks seven key manufacturing KPIs:
- Machine utilization
- Production counts
- Downtime events
- Stop counts
- Total downtime
- Total active time
- OEE (based on uptime percentage since last reset)
Power Requirements
- Because the sensor must continuously detect state transitions, it remains powered at all times using a 12VDC supply (typically via 120V wall outlet transformer)
The wireless equipment utilization sensor with downtime monitoring is ideal for:
- Equipment utilization monitoring for capital asset utilization verification.
- Continuous process production monitoring.
- Real-time production line downtime alerts.
- Downtime recording with time of downtime and duration.
- Tank and hopper bin empty condition monitoring.
- Remote monitoring of critical relay contacts and switches.
Patents pending
