We’ll mostly focus on unplanned downtime in this article but keep scheduled
downtime in mind for when we’re discussing solutions to our production
problems.
2. Record the amount of downtime for the month or consult a report from the
previous month if you have one.
3. Subtract downtime from your planned operating time. This will tell you
your actual/true operating time.
Remember, you can track downtime for individual assets as well. You can
determine which parts of your production line break the most by comparing
the metrics for different kinds of equipment.
This will be extra handy for scheduling maintenance. You can also learn
more about tracking and determining overall equipment effectiveness.
To calculate lost revenue and asset criticality:
1. Divide your total revenue by the planned operating time to get your daily
revenue.
2. Assess by how much your daily revenue goes down if the chosen piece of
equipment stops working for 1 hour.
3. Compare the results of different assets. The one whose malfunction causes
the biggest drop in revenue is the most critical part of your operation.
Now that you know which assets break the most and which equipment
failures cost you the most, you can start taking steps to improve the situation.
In some cases, error codes can help to identify problems before they cause a
machine to fail. This allows for preventive maintenance to be carried out,
further reducing downtime.
There are many different error codes, but the possible ones must be: Used
incorrectly, PM required, Didn’t follow the Policies and Procedures. If you’re
having trouble with your machine, chances are, one of them is the culprit.
Preventive Maintenance
But what does that mean? In a nutshell, preventive maintenance is all about
regular checkups and servicing your equipment in order to extend its
lifespan.
Businesses can minimize downtime and disruptions by taking steps to keep
machines running smoothly. Preventive maintenance includes regular
cleaning and inspection, as well as replacing worn or damaged parts before
they fail.
Regular Inspection
Regular inspection also ensures that machines are properly lubricated and all
parts are in good working order.
These proactive measures can minimize the risk of unexpected downtime and
keep your machines running at peak efficiency. So, the next time your
equipment shows signs of wear, don’t wait for a breakdown — schedule a
regular inspection instead.
By taking machines offline for regular checkups and repairs, companies can
avoid more costly downtime in the future.
Lack of Training
When operators are not properly trained on how to use the machinery, they
are more likely to make mistakes that can result in the machine breaking
down.
The lack of training can also lead to poor maintenance practices, further
contributing to Equipment Downtime.
Poor Maintenance
Equipment may break down for many different reasons, but poor
maintenance is often to blame. When machines are not properly cared for,
they are more likely to experience problems that could have been easily
avoided.
For example, failing to regularly oil and grease moving parts can lead to
excessive wear and tear, while neglecting to clean filters can cause them to
become clogged and overworked.
One of the leading causes of equipment downtime is excessive tool and job
changeover. When operators have to change out tools and adjust jobs
constantly, it takes a toll on the equipment and eventually leads to
breakdowns.
Changeovers can also cause quality issues if the wrong tool is used or the job
is not set up correctly. Businesses must carefully consider their tool and job
changeover procedures to minimize downtime and meet quality standards.
Simply put, if you don’t measure Machine Downtime, you can’t manage it.
The first step in reducing Machine Downtime is implementing a system that
can accurately measure and track it.
Once you have this data, you can begin to identify trends and look for ways
to improve your process. Remember, the key to reducing Machine Downtime
is to ask why it’s happening and then take steps to prevent it.
The automated machine tracking can help you identify trends over time, so
you can spot problems before they become serious.
Machine operators typically have to stop what they are doing every few
minutes to write down the machine’s current status, which can quickly
become a tedious task.
Even when operators are diligent about recording data, it is obvious to make
mistakes or forget to update the information. This can lead to inaccurate
downtime reports that don’t accurately depict the manufacturing process.
Factories can better prioritize their resources and reduce the overall impact of
downtime events by tracking machine downtime and maintenance costs.
By gathering data on when and why machines break down, factories can
develop a clearer picture of their maintenance needs.
By understanding how often machines are down and what causes them to
fail, businesses can make changes to improve the machine’s life.
In some cases, this may mean investing in new equipment. In other cases, it
may be possible to improve existing equipment by making changes to
maintenance or operating procedures.
Download template
Conclusion
Machinery downtime can cripple your business and cost you a lot of money.
It results in lost productivity, missed deadlines, and angry customers.
Machines break down, power goes out, and accidents happen. The key to
minimizing the impact of downtime is to be prepared for it.
Remember, prevention is half the battle. So prepare for the worst and achieve
the best results with Preventative Maintenance Checklist!