Tips for reducing manufacturing downtime

The manufacturing industry is constantly evolving and having to meet the demands of business, customers and technology. Downtime can be a significant obstacle to productivity and profitability and is a major priority for manufacturers when designing and producing goods. 

Several strategies and techniques can help to minimise these interruptions and keep operations running smoothly, without any costly errors. In this article, we’ll explore a range of practical tips and best practices to help you reduce manufacturing downtime whether you’re in a large-scale industrial facility or a smaller production setting.

Manufacturing downtime refers to the time during which a manufacturing process or production line is not operating at its full capacity or meeting its expected production line rate. This means the system is idle or adds no valued work. 

Manufacturing downtime can occur for various reasons, including:

• Equipment failures: This may involve mechanical breakdowns, electrical faults, and equipment malfunctions.
• Maintenance and repairs: Planned maintenance and repair activities, while essential for the long-term health of equipment, can temporarily stop production lines. 
• Changeovers: When transitioning from one product to another, changeover procedures can take time, especially if they involve reconfiguring machinery or adjusting production processes. Efficient changeover practices are essential to reduce downtime in these conditions.
• Material shortages: Delays in the supply chain, shortages of raw materials, or unexpected material quality issues can lead to downtime as production cannot proceed without these inputs.
• Quality issues: If product quality falls below certain standards, it may require production to pause while these are rectified. This can include reworking or replacing defective products.
• Human error: Mistakes made by operators or workers can lead to downtime, especially if they result in equipment damage or the need for extensive rework. This is why many manufacturing plants are now opting for a completely remote approach.
• Power outages: Like in many industries, electrical power failures or other utility interruptions can bring manufacturing processes to a halt.
• Supply chain issues: Problems with suppliers, such as delayed shipments, can impact the availability of components or materials needed for production as the production line won’t be able to start without all the necessary stages.

The best and easiest place to start is by pinpointing the main issue. What has caused the downtime to occur and how can this issue be resolved? Many businesses at this point will also need to think about their options and what’s best for production. For example, is it faster to get a maintenance worker out or replace a system completely? How will these measures affect the environment? Are there any cheaper alternatives?

In terms of maintenance, here are the two main types of maintenance that can help to reduce downtime from occurring.

Businesses should regularly schedule and perform preventive maintenance on all equipment and machinery to catch potential issues before they lead to breakdowns. This will ensure that random issues are less likely to happen as they will consistently be checked. A good comparison would be a car MOT or service.

By utilising predictive maintenance techniques, such as condition monitoring and sensors, manufacturers can predict when equipment is likely to fail, allowing for timely repairs or replacements.

Other ways to reduce and improve downtime: 

• Employee and operative training
• Implement standardised operating procedures
• Invest in reliable and trustworthy equipment
• Monitor equipment health regularly
• Keep a spare parts inventory
• Implement lean manufacturing efforts
• Use modern technologies such as IoT or automation
• Monitor and perfect the supply chain
• Carry out quality assurance checks
• Collect feedback and engagement from employees, suppliers and partners