Downtime Tracking and Analysis Software for Manufacturers

Unplanned downtime is a silent profit killer. When machines stop, every minute without production eats into your margins. The innius platform offers a dedicated solution: downtime tracking and analysis software specifically for manufacturing environments. With automated detection, structured reason capture, and deep analytics, you’ll discover not only how much downtime is occurring, but why, and where to act first.

How Innius Tracks Downtime: Four Key Pillars

To make downtime actionable, it must be detectable, explainable, manageable, and measurable. innius achieves this via four integrated functions:

1. Automatic downtime detection

2. Downtime reason definition & submission

3. Management and validation of reasons

4. Analytical reporting

Each of these are discussed below, showing how they work in practice.

1. Automatic Downtime Detection: When Does Downtime Start and Stop?

Downtime can be detected automatically based on real-time machine data. You configure this signal criteria, and logic in the innius Admin App so the system knows when equipment is idle vs. running normally. You also define your list of permissible downtime reasons and configure how sensors or system inputs will link to those reasons. This setup ensures you register stoppages consistently across your machines.

👉 Full setup instructions in the article: How to configure downtime reasons >>

2. Reason Submission from the Shop Floor: What Caused It?

Once a period of downtime has been detected, it becomes visible to operators through the innius Operations App, designed to run on tablets alongside the production line. Operators are asked to assign a reason for each period of downtime, selecting from a predefined list of reasons.

Key features:

Reasons can be fixed (always available) or dynamic, conditioned on sensor inputs.
Operators may add comments (free text) to elaborate, but cannot alter the start/end timestamps.
They can split a downtime into multiple segments if the cause changed.
Downtime events stay visible in the interface for up to 9 hours to match shift patterns without overwhelming operators.

👉 Learn more in the Knowledge Base article: “Submitting downtime reasons in the Operations App”
Submitting downtime reasons in the Operations App >>
👉 Also read: Splitting downtime into separate periods >>

3. Managing Reason Assignments: Have Reasons Been Assigned Correctly?

The Downtime Reason Manager, part of the innius Insight App, is your oversight tool. It gives a global view across machines of the downtime periods detected, which reasons have been assigned, which were left blank, and which need review.

Capabilities include:

Splitting existing downtime periods further.
Editing or adding descriptions to reasons.
Validating or correcting operator assigned reasons.

This layer ensures the data remains reliable before being used for deep analysis.

👉 See more in the Knowledge Base: Managing downtime reasons in the Insight App >>

4. Downtime Analysis and Reporting: Which Causes Matter Most?

The innius Downtime Report allows you to convert the rich data captured about downtime occurrences and causes, into actionable insights. Using the report’s Pareto analysis and shift views, you can:

Discover which causes have the greatest impact: materials, machine or personnel, etc .
Compare downtime rates between shift.
Compare the duration of downtime for each cause versus the number of occurrences.
Evaluate trends and whether causes are worsening or improving.
Filter out or include short-stop downtime.

These insights help you prioritize where to intervene, whether by process change, maintenance strategy, or operator training.

👉 Learn more in the Knowledge Base: Downtime Report >>

These companies already work with innius®

Why innius is a strong fit for manufacturers

Automatic detection reduces manual logging errors.
Structured reason capture ensures consistency and analysis readiness.
Manager oversight maintains data quality.
Actionable analytics drive targeted interventions.
Scalable and flexible – works across machines, lines, and factories.

If you’re evaluating downtime reduction tools, innius delivers a full stack; from shop floor to executive insight.

👉 Already reducing downtime? See how to cut downtime further in our downtime reduction strategies guide >>

Frequently asked questions

Hopefully you can find any answers you need here, otherwise feel free to contact us.

How can I connect my machines to innius?

If your machines generate a data stream and can be connected to the internet, normally via a PLC and an Ewon Flexy or Ixon modem, then they should be innius capable.

To help you, an Innius Feasibility Study is available, find out more on our Getting Started page.

Do I need any other hardware, once my machines are connected?

innius is a cloud computing based service, so there is no requirement for on-premises servers. Just a mobile devices or a desktop computer to work with innius.

Can innius data be shared?

Yes, through the trusted relationships and machine sharing system, it is possible to share selected data with other entities. For example: a factory wants to share machine performance data with a machine maintenance company.

Who owns the data?

You remain the owner of all data generated. Innius will not share it.

What about security?

The main thing to consider is that innius only reads your machine data, it can’t send anything back to your PLC or machines, which obviously has huge security advantages.

In addition to that a number of industry standard security steps have been taken. These are fully detailed in the Knowledge Base. Or if you want to know more talk to us.

What is the pricing model?

innius operates on a monthly subscription pricing model, giving you access to all the apps. The cost depends mainly on the data usage in addition to a number of other factors. Please get in touch to talk about your specific needs.

My production line is a mix of both hi-tech and older machinery. Isn’t that a problem?

No, you don’t need to connect everything in a production line. innius can deal with individual machines.

Can I connect innius to other software?

Innius seamlessly integrates with your digital ecosystem through APIs and webhooks. Share data with analytics tools such as Power BI and trigger tasks in EAM and MMS software.

Richard Crowter, UX Designer & Marketing Coordinator at innius

Curious what innius means for your business?

This is Richard, he’s happy to advise you! Please fill out the form and he will be in touch!