It is easy to think that the main causes of unplanned downtime on a production line is equipment failure. After all, massive machines with complex functions seem inherently prone to breakdowns.

It should be noted, however, that mechanical and electrical faults are not the main reasons for downtime. A wide variety of different problems have the potential to disrupt production and result in unexpected machine downtime. This disruption can have a major impact on your bottom line and customer satisfaction. So, let's delve in deeper to the real causes of machine downtime:

The causes of machine downtime in business:

1) People

A key employee missing a shift due to illness can throw a spanner in the works of an otherwise healthy production line. Bringing in a temporary worker is a common measure that is taken to address this issue. Another option is to have someone from a different department within the company to get things back up and running. But if the replacement doesn’t have the right training or experience, this increases the chance of human error.

Incorrect adjustment, maintenance, or operation of equipment can result in a much longer period of downtime. According to a survey by GE Digital, it was found that human error was responsible for 23% of all unplanned downtime [1]. This finding sheds light on the major impact that human errors can have on operational procedures.

However, there are proactive measures that can be taken to lessen the chance of this risk occurring. By implementing thorough training programs, clear procedures, and robust communication channels, manufacturers can empower their staff. This will result in a major decrease in the amount of downtime that is caused by human error.

2) Supply chain disruptions

Just-in-time production and lean manufacturing both rely on supply chains that are efficient and sometimes are a reason for downtime. Small delays in the delivery of raw materials, parts, or assemblies, can have significant knock-on effects. One of the key causes of machine downtime is the equipment that has become stalled because of missing production inputs.

Toyota first implemented lean manufacturing in the 1960s, and it has since become standard across the automotive sector. This approach prioritizes efficiency and minimal waste, often keeping inventory levels low.

However, this very reliance on a smooth supply chain can leave manufacturers vulnerable to disruptions. A prime example of this is the recent global shortage of semiconductor chips. Despite their well-honed lean practices, Toyota was not spared. In the year 2022, it had a halt in production and a significant, 25% decrease in profit [2].

3) Environmental factors

When equipment is running, circuity and moving parts get hot and need cooling down. However, when the temperature outside is too hot, cooling the equipment can be hard. In 2022, a heatwave in London overwhelmed Google and Oracle data centres and caused some systems to shut down [3]. This highlights how important it is to consider the operating environment when selecting machinery.

In the same way, when the weather is cold, it is common for machinery to struggle to start and even seize. Machinery can also be sensitive to humidity (which causes condensation and corrosion), dust and other atmospheric pollutants.

4) Utility shortfalls

Most production equipment relies on electricity to run, and lots of it! Energy-intensive manufacturing operations are frequently disrupted in nations that experience problems with their electricity supply. In 2021 increased demand for electricity and price controls caused electricity shortages in China.

The production of steel, aluminium, cement, and fertilizer suffered as a result [4]. Disruptions to other key utilities like natural gas, water, telephone, and internet communications can also cause downtime in business.

This can be a major setback for businesses, leading to production delays, lost revenue, and damage to reputation. In extreme cases, utility shortfalls can even force businesses to close their doors permanently.

5) Software issues

Software is an essential to modern supply chains as it allows for the monitoring and control of production processes. Despite the fact that this software will be subject to extensive testing, it is rarely perfect. Glitches, maloperations, and incompatibilities with other hardware and software are common reasons for downtime in business.

When it comes to troubleshooting these issues, it can be extremely stressful, and they can drastically slow down production. In some cases, they may even lead to damaged or unusable products.

Mission-critical software is another target for cybercriminals. Recent cyberattacks have targeted a number of companies, including Clorox, a company that manufactures cleaning goods. The digital intrusion caused operational and supply issues, resulting in millions of dollars in lost revenue. [5]

6) Planned maintenance

There are instances when businesses purposefully choose to have downtime. To avoid unplanned downtime, equipment must be regularly inspected, maintained, upgraded, and eventually replaced. Planned maintenance can impact production volumes in the short term, to avoid much bigger problems further down the line.

While it may be inconvenient, it is a necessary step to take to keep manufacturing lines running smoothly and equipment lasting longer. Unanticipated breakdowns can cause major disruptions and financial loss. But, firms can reduce this risk by proactively addressing possible disruptions.

To give one example, Tesla's output of vehicles in 2023 was far lower than expected. [6] The primary reason for this was that the company's plants in Texas and Shanghai were scheduled to undergo planned maintenance.

7) Equipment failure

Of course, it is inevitable that there will be times when machines malfunction. Ageing and use are the only factors that are considered to be potential causes of equipment failure. You can extend equipment lifecycles and anticipate downtime with a strict inspection and maintenance program. This program should include regular check-ups, lubrication, and parts replacements to minimize the risk of unexpected failures.

Regular maintenance can also help identify minor issues before they turn into major equipment failures. As a result, this will lead to time and cost savings for companies in the long run.

Unintended reasons for downtime include improper usage or storage, fire or water damage, and contamination. These unexpected events can cause significant disruptions and can be very expensive to repair.

Good planning and predictive maintenance mitigate many of the real causes of machine downtime. Using data analytics and artificial intelligence can also help to assess the risk of downtime in business.

[1] "After The Fall: Cost, Causes and Consequences of Unplanned Downtime”, 2017, a study by Vanson Bourne for GE Digital [2] "Toyota profit plunges 25% on chip shortages and surging costs”, 1 November 2022, Financial Times [3] "Heatwave forced Google and Oracle to shut down computers”, 20 July 2022, BBC News [4] “China power cuts: What is causing the country's blackouts?”, 30 September 2021, BBC News [5] “Clorox, reeling from cyberattack, expects quarterly loss”, 4 October 2023, Reuters [6] “Tesla Deliveries Slide as Factory Downtime Slows Production”, 2 October 2023, Bloomberg