This article explores machine utilisation monitoring and answers, what it is, why it matters and how manufacturers are doing it today.
Manufacturers know they can’t improve what they can’t see, yet most still struggle to answer the simplest question about their factory: “Are our machines being used effectively?”
Across every sector, from aerospace to electronics to food and drink, manufacturers are actively searching for ways to track machine utilisation in real time. Many are stuck with manual logs, paper downtime sheets or spreadsheets that are hours, or days, out of date.
What Is machine utilisation monitoring?
Machine utilisation monitoring, or machine downtime monitoring as it is also commonly referred to is the process of measuring how much time a machine is actually being used for productive work compared to how much time it’s available.
At its simplest, utilisation answers three questions:
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When is the machine running?
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When is it idle?
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When is it stopped, and why?
Traditional approaches rely on operators filling in forms, manually logging downtime or inputting data into Excel. But this creates challenges:
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Data is subjective
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Accuracy varies by operator
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Large amounts of downtime go unrecorded
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Real-time visibility is impossible
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CI teams can’t trust the data to make decisions
That’s why so many manufacturers are now looking for automatic, real-time utilisation tracking.
Why machine utilisation matters
Machine utilisation sits at the heart of manufacturing productivity. Even a small improvement can translate into large gains in capacity.
Here’s why it matters:
It reveals hidden downtime.
Even today, most factories underestimate how much time machines sit idle. Common causes include:
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Waiting for operators
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Waiting for material
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Changeovers
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Process delays
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Breakdowns
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Programming/setup
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Tool changes
By having a system in place that monitors utilisation ensures these losses instantly are instantly exposed.
It helps prioritise improvement work
When CI teams know which machines (or shifts) consistently underperform, improvement efforts become laser-focused, not spread thin across the factory. Managers have the facts they need to focus on which inefficiencies they should prioritise first, based on the impact they're having on capacity/production efficiency.
It increases throughput without new machines
Many manufacturers think they need more equipment. But utilisation usually tells a different story:
Machine utilisation data from across our customer base shows that without monitoring in place, most factories only utilise 20–40% of their machine capacity. Unlocking even a fraction of that unused time delivers significant extra output, without capital expenditure.
Read what our customers have achieved here.
It’s the foundation of OEE
OEE (Overall Equipment Effectiveness) is widely used, but it starts with one basic requirement: accurate utilisation data. If utilisation is wrong, every OEE number is wrong.
How manufacturers are tracking machine utilisation data today
Based on hundreds of inbound conversations, manufacturers typically fall into one of four categories.
01. Paper and manual logs
Operators record hours, downtime and issues on paper forms. This presents several challenges:
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Time-consuming
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Often incomplete
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Not real-time
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Hard to standardise
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Accuracy varies by operator
This method produces data that cannot reliably support decision-making.
02. Spreadsheets and Excel
Some teams digitise paper data manually into spreadsheets, but again, this has its own set of challenges:
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Still relies on subjective operator input
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Very slow
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No live data
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Hard to extract insights
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Prone to transcription errors
Many manufacturers told us they want to eliminate Excel-based production tracking entirely.
03. Machine control data (PLC/CNC integration)
Modern machines can output run states, alarms and part counts.
Challenges:
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Only works for newer equipment
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Not feasible for mixed environments
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Requires IT support
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Integration complexity and cost
Most factories have a blend of machine ages, brands and control systems — so PLC-based solutions only cover a fraction of the shop floor.
04. Universal ,real-time machine utilisation systems
These systems, like FourJaw (that's us!) automatically track run/idle/stop states by sensing machine power signals.
Benefits:
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Works across every machine (CNC, manual, packaging, presses, printers, bottling lines)
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No PLC integration
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Live data with zero operator admin
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Optional operator tablets for downtime reasons
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Simple to install and scale
This is rapidly becoming the preferred approach for manufacturers who want a fast, reliable way to get utilisation and OEE data. But don't just take our word for it, take a look at some of our testimonials and customer case studies to see for yourself.
Summary
Machine utilisation monitoring is becoming a fundamental requirement for modern manufacturing. It gives teams the real-time visibility they need to make faster, more confident decisions and it allows factories to unlock thousands of hours of capacity without additional capital expenditure.
Manufacturers increasingly want a single, simple, universal solution to track every machine — not fragmented systems or unreliable manual data.
The shift is clear:
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From paper → digital
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From manual → automatic
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From retrospective → real-time
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From local spreadsheets → connected platforms
Factories that embrace real-time utilisation unlock opportunities for faster response, deeper insights and continuous productivity improvement.
For manufacturers stuck in spreadsheets, manual logs or incomplete downtime data, the path forward is simple: Start by making machine utilisation visible. Then everything else gets easier.
