Unplanned downtime is the time when a manufacturing machine, network or other piece of equipment stops working unexpectedly. It’s a significant problem for manufacturers as it can delay production and cause issues further down the production process. It also costs money, both in the cost of fixing the problem and in lost production capacity. As a result, manufacturers try to minimise unplanned downtime as much as possible.
With thorough planning and new technology, companies can do more to reduce unexpected downtime than ever before. In this article, we’ll explore some of the remedies.
Causes of unplanned downtime
The most prevalent cause of unplanned downtime is equipment failure. Manufacturing equipment is always prone to wear and tear; parts degrade over time, and one component failing can send the whole machine down.
Another common cause of unplanned time is human error. Sometimes people push the wrong button, or force something through a machine that shouldn’t be there, causing it to break. It’s also common for power cuts to lead to long-term malfunctions in machines, as the outage can affect its circuitry.
Impact of unplanned downtime
Unplanned downtime can be devastating to a manufacturing company in terms of time and money. Here are some of the effects that can happen:
- Production capacity – Unplanned downtime can impact the entire chain of production, causing you to miss output targets
- Damaged machines – Fixing damaged machines can take a long time, particularly if there are lots of components
- Supply chain – If one part of the production process stops unexpectedly, it can halt work further down the production chain
- Productivity – Unplanned downtime lowers productivity and efficiency in your production process
- Cost – Unplanned downtime incurs expenses in lost production, lost sales, higher labour costs and the cost of repair. It can also cause reputational damage to the company
So, what can you do about it?
Minimising unplanned downtime
Reducing unplanned downtime requires a multi-faceted approach. The first step is to analyse your processes and switch from being reactive to proactive. Collect as much data as possible on your machines’ performance and usage. Use the data to identify the root causes of unplanned downtime, then take action to stop it.
This could involve more proactive maintenance plans; servicing your machines more regularly so component wear and tear doesn’t happen. You could perform maintenance at off-peak times to minimise any planned downtime. You could also adopt lean manufacturing principles, including standard work, to create a consistent framework for performing tasks, reducing the risk of human error and inefficiency.
However, the most significant impact on your unplanned downtime will come from the use of technology. Use IoT and AR monitoring technology to get real-time visibility into your machines' performance. This will help you spot the signs of malfunctions, so you can fix small problems before they become big ones.
Look to the future
When you invest in the right technology to minimise unplanned downtime, you’re likely to see significant returns. You’ll be more efficient and productive, you won’t spend as much time and money fixing problems, and your people will make fewer errors.
The manufacturing industry is already looking at AI-powered integrations to help predict and minimise unplanned downtime by spotting patterns in the data and picking out anomalies, which could be signs of potential machine failure. 