Nobody logs a ten-minute stop. The machine hiccups, someone clears it, the line moves again — and the day's production report pretends it never happened.

Here's the math nobody does: ten minutes, three times a shift, across three shifts, five days a week. That's seven and a half hours of lost output a week. A full shift of production, gone — not to breakdowns anyone would call maintenance about, but to stops too small to write down.

Big breakdowns get attention because they're dramatic. The small stops stay invisible because each one feels too minor to report. But they're the ones that repeat. Same sensor, same jam, same settings drift — week after week, because nobody sees the pattern. Patterns only show up in data, and the data was never written down.

Start with a clipboard at the end of the line. Time, line, what stopped, how long. One week. You'll find the same three problems causing most of the stops — and fixing the top one is usually a settings change, a worn part, or a five-minute conversation with the night shift.

The expensive downtime isn't the big dramatic failure. It's the small boring one, happening every day, that nobody ever logged.