The reality is, downtime is an unavoidable reality for any business that relies on machinery and equipment. But excessive downtime, especially unplanned, can be detrimental to a business. It leads to lost production time, delays in project completion, and potentially missed deadlines. Additionally, the costs of emergency repairs and overtime for staff can add up quickly. For example, in manufacturing, even a single hour of downtime can cost thousands of dollars in lost production.
However, understanding and managing downtime can significantly improve productivity and save costs. In this post, we'll explore what downtime is, why it’s costly, and practical ways to reduce it.
What is equipment downtime?
Equipment downtime is the amount of time in which machinery or equipment is not operational and unable to perform its intended function. Downtime can result in production delays, decreased efficiency, and increased costs for repairs and lost productivity.
There are two types of equipment downtime:
- Planned downtime refers to scheduled interruptions for maintenance, upgrades, or other necessary activities. These are expected and can be managed to minimize impact on operations.
- Unplanned downtime, on the other hand, is unexpected and often results from equipment failures or unforeseen issues. This type of downtime can be particularly costly because it disrupts production schedules and leads to unexpected repair expenses.
6 ways to reduce equipment downtime
If your business is suffering from lost profits due to equipment failing, you have options. The following are many ways you can try to mitigate lost time and money due to faulty equipment.
- Track downtime
The first step in reducing downtime is tracking it. You can't fix what you don't measure. Implementing a CMMS (Computerized Maintenance Management System) can help record and identify reasons for unplanned downtime. By analyzing this data, you can pinpoint recurring issues and develop strategies to address them.
- Conduct a Risk Audit
Identify which machines are most critical to your operations and which are the oldest or most obsolete. Equipment that lacks support or is prone to failure should be prioritized for replacement or more frequent maintenance. A risk audit helps you understand where to focus your efforts for maximum impact.
- Schedule Regular Preventative Maintenance
Regular preventative maintenance can catch potential problems before they lead to unplanned downtime. Schedule routine checks and services for all machinery based on the manufacturer's recommendations and your operational data.
- Create a Visual System for Downtime Alerts
Ensure all operators are immediately aware when a problem arises by creating a visual alert system. This could be as simple as indicator lights on machines or a digital dashboard that shows the status of all equipment in real-time.
- Establish Tools and Processes for Unscheduled Downtime
When unplanned downtime does occur, having the right tools and processes in place can minimize disruption. This includes having a response plan, trained technicians available, and spare parts on hand to expedite repairs.
- Clean Up Your Energy Supply
Dirty power can contribute to equipment failures and unplanned downtime. Using solutions like Electripure’s CleanPQ harmonics filter can stabilize your power supply, reducing the risk of voltage spikes and surges that can damage equipment.
Downtime sucks—but by tracking downtime, conducting risk audits, scheduling regular maintenance, and using tools like Electripure’s CleanPQ harmonics filter, you can significantly minimize both planned and unplanned downtime. Remember, incremental changes allow you to effectively gauge improvements and optimize your strategies over time. Eventually, your reducing equipment downtime will lead to maintaining productivity and controlling costs.
Ready to downtime-proof your facility? Electripure’s experts are ready to help you not only reduce your downtime but also lower your power bill by up to 20%! Give us a call and we can help you get your money’s worth out of the power you pay for.