NRTC AUTOMATION BLOG | INDUSTRIAL ROBOTS AND AUTOMATION
5 Ways to Minimize Downtime in Manufacturing
Knowledge and attention to detail are two key characteristics of manufacturers with minimal downtime in their facilities.
Knowledge and attention to detail are two key characteristics of manufacturers with minimal downtime in their facilities.
Downtime might be considered the bane of every manufacturers’ workday.
A small event can be a nuisance, while a major downtime occurrence can ruin a company’s yearly profit. It is always a risk, especially when facilities are highly automated.
However, that doesn’t mean manufacturers are powerless to prevent it. With a few simple tips, you can improve productivity and minimize downtime in your facility.
5 Ways to Minimize Downtime in Manufacturing
What is downtime?
Unlike the restful vision of personal downtime, downtime in manufacturing is very different.
In manufacturing, downtime is when industrial machinery is not in production. Downtime can be planned, such as for repairs, or it can be unplanned, such as due to equipment failures or power outages.
Planned downtime is necessary to maintain and repair equipment. With preparation, manufacturers can outmaneuver the harmful effects of downtime.
However, unplanned downtime is detrimental to any company’s bottom line.
Dangers of downtime
Above all, downtime is expensive.
The average cost of a downtime incident is $17,000. Couple that with the fact that 70% of companies are unaware of the maintenance schedule for their industrial equipment, and you get a costly stain on your production quota.
Downtime is also highly inefficient. When equipment isn’t working, manufacturers are increasing lead time and missing out on precious production time.
This can create angry customers who aren’t receiving their products on time. Depending on if they leave negative reviews, you can miss out on new customers exponentially.
How to minimize downtime in your facility
In order to stay ahead of unplanned downtime, being prepared is key.
1. SET GOALS
Setting goals is necessary to achieve minimal downtime in manufacturing.
Identify your production goals in terms of lead time and total output, and make a daily, weekly, and monthly numerical goal based on them.
When you have goals like reducing lead time by 20 percent or doubling total output, you will be inclined to search for wasted time, motion, or energy if you don’t meet your goals.
This will minimize downtime by keeping you and your team engaged with the production line.
2. AUTOMATE
It is always recommended to automate if you have highly repeatable, monotonous, and/or dangerous tasks in your manufacturing facility.
For example, welding auto parts can easily be automated with a robotic work cell, cutting down on lead time and enhancing your product.
NRTC Automation can build a custom robotic work cell for your company’s specific needs. By using refurbished industrial robots and manufacturing equipment, you can automate at a fraction of the cost of using brand-new equipment. Plus, we offer financing so you can improve productivity and grow your company with low monthly payments.
Visit our Automation Services page to learn more!
3. TRAIN EMPLOYEES
Well-trained employees are better prepared to handle equipment failures, drastically reducing downtime when it occurs.
Rather than having to hire and wait for an outside technician to fix your production line, your employees can troubleshoot and repair in-house.
Plus, your staff will have a keener eye on manufacturing processes and be equipped to make changes if they notice wasted product or movement on the line.
Are you looking to train your employees in robotics? We can help! Visit NRTC Automation’s Robotic Training Services page to find out how we can assist your company.
4. STUDY DATA AND TRACK DOWNTIME
Data is the most important asset you have. It gives you the ability to track downtime and adjust as needed to enhance the performance of your equipment.
Meet with your team regularly to review production data. Making changes will be easier when everyone is on board and understands the costs of downtime in real time.
5. KEEP A MAINTENANCE SCHEDULE
Finally, keeping a maintenance schedule will protect your equipment from failure and protect your wallet from hefty repairs or replacements.
Store equipment manuals in a central location and note how often each robot and piece of manufacturing equipment needs to be maintained.
Staying on top of maintenance will extend the life of your equipment and minimize downtime and equipment replacements in the long run.
Get ahead of the competition
Minimizing downtime isn’t difficult; in fact, most downtime can be prevented with knowledge and attention to detail.
By using our tips above, you can improve your lead time, increase production output, and grow your company while avoiding unplanned downtime.
AUTOMATE WITH NRTC TODAY
NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.
From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services.
Get financing with NRTC when you order a custom-built robotic work cell with us.
3 Ways to Reduce Downtime in Your Production Line
While downtime is a constant, it doesn’t have to consume your production line. NRTC Automation has three tips that will help reduce downtime in your manufacturing facility.
Downtime is the menace of manufacturing, but with preparation, manufacturers can save money and keep loyal customers.
Everyone loves downtime—relaxing on the beach, reading a good book, or taking a nap are all ways to rest the body and mind after a long day.
Everyone, that is, except for manufacturers. Downtime means halted production and massive cuts in profit in the world on manufacturing.
While downtime is a constant, it doesn’t have to consume your production line. NRTC Automation has three tips that will help reduce downtime in your manufacturing facility.
Read more about the costs of downtime and how to prevent it below!
Downtime in Manufacturing
Downtime is any time that a robot, computer, or piece of equipment are not available for use. Unplanned downtime occurs when operators do not intend to shut down equipment, such as for repairs, and can be particularly heinous on manufacturers’ wallets.
In fact, unplanned downtime cost businesses on average $260,000 an hour in 2016!
Naturally, manufacturers are on high alert for any downtime in their production line to prevent these mammoth losses.
True Cost of Downtime
What’s hidden in that large profit loss? Why does downtime cost manufacturers so much money?
There are three big reasons why downtime dramatically cuts revenue:
Lower production output
Loss of customers
Lower production output means less product is being manufactured, so fewer sales are made. When the factory is running and employees are on the clock, this leads to a net loss in revenue.
Downtime also causes decreased employee productivity. When production is halted, employees are no longer focused on tasks and spend their time waiting for work to start again. Regaining focus to normal productivity levels takes time, causing a loss in profit.
When customers are affected by downtime, they may decide to find business elsewhere. This is a huge loss for companies, especially when they lose lifetime customers. If unplanned downtime forces your customers to look for products or services elsewhere, then you can expect to see revenue cuts for years to come.
3 Ways to Reduce Downtime in Your Production Line
Thankfully, there are ways to reduce unplanned downtime in your production line. Save money and keep your loyal customers by implementing these three tips into your manufacturing business.
1. GET AN INDUSTRIAL COMPUTER WITH COMPUTERIZED MAINTENANCE MANAGEMENT SOFTWARE, OR CMMS.
With CMMS, you can track all kinds of data that will protect your company from unplanned downtime. You’ll get alerts when equipment needs repair, keep an eye on production numbers, and see where energy is being wasted.
Productivity and data-tracking software is your best friend in manufacturing. Use technology to your advantage.
2. KEEP A MAINTENANCE SCHEDULE FOR YOUR EQUIPMENT.
Equipment maintenance is easy when it is accounted for. When repairs come up suddenly without warning, taking a piece of equipment out of the production line can lead to lengthy downtime, especially if you don’t have robotic technicians on hand.
Read your manufacturers’ manuals and keep a strict schedule for maintaining your equipment. Not only will it save you money by extending the life of your equipment, but it will also cut down on unplanned downtime.
3. TRAIN EMPLOYEES IN HANDLING AND MAINTAINING EQUIPMENT.
Your employees can be your biggest asset... if you let them. Train your employees to handle equipment carefully and educate them on the basics of equipment repair and maintenance in between trips to the technician.
When employees are empowered to handle problems on their own, you don’t have to rely on outside help to fix malfunctioning production lines.
Don’t let downtime get in your way.
Downtime is a struggle for all manufacturers, but with preparation, you can limit its effects on your company. Reduce downtime by using productivity software, keeping a maintenance schedule, and training employees.
Be smart about your manufacturing process, and you can prevent unplanned downtime and keep money in your pocket.
VISIT NRTC AUTOMATION FOR ROBOTIC ENGINEERING SERVICES.
If you have a technical problem, we can fix it! NRTC Automation’s team of reliable and professional technicians is ready to help troubleshoot and resolve any technical issue you encounter. We’ll work to minimize downtime and get your production line back up and running.
Visit NRTC Automation today to learn more about our automation services.