Planned vs unplanned downtime in manufacturing
July 9, 2024
Updated on: July 9, 2024
3 min read
While it’s easy to see all forms of stoppage as bad for business, not all machine downtime is created equal. There is an important distinction that separates planned vs unplanned downtime in manufacturing.
Unplanned downtime in manufacturing
Unplanned machine downtime can be quite disruptive and costly for production. It occurs when equipment fails, breaks down, or when emergencies arise.
Identifying the issue, sourcing replacement parts, and restoring operations to full capacity can be time-consuming. It could take a few hours or possibly a few days to complete the process. When a critical machine fails without warning, it demands immediate attention.
It can be quite challenging when there is a need to find qualified technicians, expedite repairs, and possibly even halt production on entire lines. The resulting delays can have a ripple effect. They can push back deliveries, frustrate customers, and impact the company's bottom line.
Planned downtime in manufacturing
It is not uncommon for us to be caught off guard by unplanned machine downtime. However, planned downtime is something that we anticipate well in advance. It is an essential part of maintenance that drives continuous improvement and helps ensure a safe working environment.
Consider it to be similar to making a pit stop in the middle of a major race. It is a brief break to adjust equipment, improve efficiency, and avoid unexpected malfunctions.
Manufacturers can take advantage of scheduled machine downtime to conduct thorough equipment inspections. In addition to replacing worn-out components, technicians can also implement preventive measures. These measures include cleaning, lubrication, calibration, and software updates.
During scheduled downtime, you have the chance to evaluate and control your spare parts inventory. This can help you make the most of your time and resources. An additional benefit is that it makes it possible to train engineering teams. This ensures that their knowledge of the latest maintenance techniques and technologies remains up-to-date.
Incorporating new technologies or optimising existing processes is another great opportunity that planned downtime offers. This can result in improved overall equipment efficiency (OEE), increased product quality and reduced unplanned downtime and energy consumption.
The power of predictive maintenance
You should see planned downtime as an investment in the long-term health and competitiveness of your manufacturing operation. This proactive strategy helps prevent equipment failure and significantly lowers the risk of unexpected breakdowns.
The challenge lies in executing planned downtime swiftly and efficiently with minimal disruption to overall production. Doing so requires careful planning and a robust preventive maintenance programme. As well as, routine audits of the equipment to discover any potential problems before they become more serious.
Predictive maintenance technologies are a powerful new addition to the maintenance toolkit to help address downtime in manufacturing. Real-time insights into the health of equipment can be obtained through the use of predictive analytics and condition monitoring.
The addition of remote monitoring and control technologies reduces the dependence on physical presence and manual information gathering. When problems arise, manufacturers have the ability to quickly intervene and find solutions before they become critical. This is possible by detecting anomalies and potential failures before they occur.
