Industrial downtime, how to prevent it
Unscheduled industrial downtime goes beyond an inconvenience for the manufacturing world. Many factors influence and prolong some business interruptions, with negative repercussions in the short and long term. Lack of raw materials, human error, and hardware and software malfunctions are the most common causes of production stoppages, depending on the business processes and individual sectors. It is upsetting and annoying for entrepreneurs and customers to face it because downtime undermines corporate credibility and results in higher-than-expected costs. Therefore, one can speak of tangible damage in the short term – because of economic losses – as well as intangible damage in the long term – once a company loses its brand image. Awareness of the risk can spur companies to invest in prevention – especially the training of human resources – and effective technologies that enable timely repairs.
Industrial downtime, the means to prevent it
Manufacturing companies cannot achieve anything without planned maintenance, also known as predictive maintenance. Troubles, such as industrial downtime, can be anticipated thanks to sophisticated systems that make use of
– Intelligent sensors that collect advantageous data for production analysis
– Monitoring that relies on real-time information that optimizes operations
Statistically speaking, up to fifty percent of casesmachine downtime is related to problems with hardware and software systems. However, the human factor is not a secondary parameter, so emphasizing professional training according to set time intervals is vital. That is a priority criterion for predictive maintenance, which differs from reactive maintenance. In the latter case, action is taken when a fault has already occurred. The risk that atmospheric agents and natural disasters can pose is no less reasonable, although less likely than other causes.
How long does industrial downtime last?
When faced with the risk of industrial downtime, it is legitimate to ask how long it can last. There’s no immediate answer because a hasty assessment can generate an equally hasty response. The likelihood of underestimating the inconvenience is not so remote. It may happen that, at first glance, a problem appears solvable within a few days. In some cases, the situation may turn out to be more complex, as one or more complications may arise. Therefore, you should think carefully before contacting the customer and giving the wrong feedback. Responsiveness and fairness towards customers are two values for a company like LGA that strives to provide continuous support. Furthermore, our company is committed to preventing software and hardware damage, the latter due to poor environmental conditions or insufficient attention to parameters such as temperature and humidity. Focus on Avoiding Wear and tear components by encouraging investment and improving monitoring.
The crucial role of training and AI
In addition to operational investments in devices, training plays a crucial role. Therefore, untrained personnel and resources cannot take timely action to restore productivity quickly. Therefore, this is the worst scenario that may determine unplanned industrial downtime over a more durable period of time. The intervention capability depends on the knowledge of individual processes. When it comes to emergency situations, it is a redeeming factor for the company’s image. Consulting reinforces the relationship with the customer, who can rightfully expect
– Use and application of Machine Learning and Artificial Intelligence (AI) to identify patterns and predict failures
– Application of advanced algorithms to optimize maintenance cycles that facilitate planning for operational phases
– Use of highly efficient devices and materials
– Study of product characteristics, including coatings and surfaces
Dated machinery: additional costs and scarce spare parts
When talking about unplanned industrial downtime, losses and costs that forced shutdowns can entail come to mind. Several renowned studies have shown that some IT companies may incur incremental and unplanned costs amounting to tens of thousands of dollars per hour. Multinationals pay a hefty bill, as do manufacturing companies operating in multiple markets. Smaller costs affect small and medium-sized companies, but consider that expenses are always proportional to the resources invested with inevitable repercussions on budgets. Checking the status of machines, dedicated software updates, and identifying obsolete processes help define the risk and counter it. Furthermore, it is a good habit to assess the availability of spare parts. Scarce spare parts indicate that a machine is outdated. Unplanned industrial downtime, unlike planned downtime, implies a concerted effort and constant vision.
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