Intermittent Sensor False Alarms
Safety sensor gave intermittent false-negative readings (sensor signal lost momentarily), triggering automatic equipment shutdown. This occurred 5-6 times daily, causing brief stoppages. Each time, line operators restarted the equipment. Sensor was due for replacement per maintenance schedule, but intermittency was treated as 'normal operation.'
What Became Visible
Micro-stop data correlated with equipment error logs. Pattern: Every micro-stop was preceded by a sensor signal loss event. The sensor was failing (intermittent contact) but only partially—still registering most of the time. Pattern recognition revealed the sensor as the micro-stop cause.
Predictive Sensor Replacement
Sensor replaced immediately based on pattern recognition, not waiting for complete failure. New sensor provided consistent, reliable signal.
How it worked: Systematic micro-stop + error-log correlation identified the intermittent sensor as root cause. Replacement eliminated the intermittency.
Results
from sensor cause elimination
no false alarms
Intermittent sensor failures cause micro-stops. Correlation between micro-stop patterns and error logs reveals the root cause.
Operational Reality
The sensor was on the maintenance schedule for replacement. Early detection and replacement prevented weeks of micro-stops.