MES, MOM & Shop-Floor Data Systems worked example

Downtime Code Accuracy at 18% investigation and correction allowance: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop investigation and correction allowance to 18%, then walk the calculation through step by step. Estimate the time needed to audit and correct downtime reason codes, ensuring coded reasons accurately reflect actual failure modes for reliable analysis.

The inputs for this scenario

  • Downtime events to audit per week: 85 events / wk (held at the documented default)
  • Events reviewed per minute: 1.5 events / min (held at the documented default)
  • Investigation and correction allowance: 18 % (the input this scenario stresses; the baseline uses 25)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base audit time = events to audit / events reviewed per minute.
  • Total weekly audit time works out to 66.87 hr at these inputs, and this is the headline figure for the scenario.
  • Base audit review time works out to 56.67 hr at these inputs.
  • Investigation and correction allowance works out to 18 % at these inputs.
  • Audit review rate works out to 1.5 pieces / min at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where investigation and correction allowance sits at 25% and the headline result is 70.83 hr, this scenario comes in 5.6% below the baseline at 66.87 hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to investigation and correction allowance, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a steady review rate; ambiguous or chronic micro-stop events take far longer to investigate than the average implies.

Results at a glance

  • Total weekly audit time: 66.87 hr (headline result)
  • Base audit review time: 56.67 hr
  • Investigation and correction allowance: 18 %
  • Audit review rate: 1.5 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Downtime Code Accuracy calculator, set investigation and correction allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.