The stop was recorded after the fact.
Across two plants and six lines, packing and maintenance could not see the same stop. The machine, its reason and the minutes were not held together in a record that both teams could use.
Planned stops had an allowed duration. When a stop ran beyond that allowance, the excess time did not stay attached to the machine. On milk packing, printer stops alone accounted for 3,664 minutes in the first month. Curd losses included power, hot water, batch delays and the incubation room.
The reason and the extra minutes stayed on the machine.
Neuron recorded the operator’s selected reason alongside the stop’s start, end and duration. Minutes beyond the allowed time remained on that stop. Packing could see the lost time; maintenance could see its cause, using the same machine record.
The records made the specific losses measurable through the year. Milk printer-stop time fell to 135 minutes. On curd, power-stop time fell from 1,802 to 52 minutes and hot-water overruns from 3,373 to two minutes. Batch-delay and incubation-room losses reached zero.
Milk and curd showed different parts of the gain.
Milk unplanned stops fell from 2.8 hours a day to 0.5 across 14 packing heads. The separately reported unplanned-downtime measure moved from 4.1 to 3.0 hours a day.
Curd packing OEE rose from 70% to 84% across eight machines. For the two-plant operation, the case reports ₹1.83 crore in additional monthly revenue over the one-year comparison.
The losses, measured on the machines.
| Measure | First month | Last month |
|---|---|---|
| Milk: unplanned stops / day | 2.8 h | 0.5 h |
| Milk: unplanned downtime / day | 4.1 h | 3.0 h |
| Milk: printer stops | 3,664 min | 135 min |
| Curd: OEE | 70% | 84% |
| Curd: power stops | 1,802 min | 52 min |
| Curd: hot-water overruns | 3,373 min | 2 min |
Godrej Jersey, two plants and six lines, one-year comparison. Milk covers 14 packing heads; curd covers eight packing machines. Daily hours are monthly minutes divided by calendar days: 31 in the first month and 30 in the last. Unplanned stops and unplanned downtime are separate measures in the source.
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