Production downtime — where to look for their causes?

According to a report prepared by the Federal Emergency Management Agency (FEMA), more than 40% of enterprises that have experienced a major accident do not “recover” again. Length of downtime is critical to the survival of an organization. What are the most common causes of industrial failures and what damage can they cause?

Unplanned downtime affects the business continuity of an industrial enterprise, causing not only large financial losses, but also affecting the company’s reputation and the trust of its customers.

Common causes

Calculating production downtime is critical. To minimize overall losses and reduce costs, first identify the root cause of downtime. Although we are not always able to prevent them, it is possible to effectively reduce their impact on the company’s operations. One of the key issues in reducing the risk of production downtime is establishing clear communication practices and regularly maintaining tools and equipment.

The most important causes of downtime are:

  1. Inadequate layout of the production space
    The efficiency of production largely depends on how the various machines, production equipment and the employees who support them are located in the plant. Only a properly planned installation can ensure a fast and smooth flow of material from raw material to the final product. Wasting a few seconds moving from one place to another may not seem like a big deal at first, but over time it will make it very difficult to perform surgery. Therefore, to maximize efficiency, it is necessary to properly plan the production space.

Actual costs

As a result of unplanned downtime, no value is produced, but overhead costs continue to rise, directly affecting the bottom line. According to a 2017 study by the research firm Aberdeen Research, 82% of companies have experienced unplanned downtime in the last three years, and the average cost to a company is $ 260,000 an hour!

At the same time, according to the report “Failure Analysis Market by Equipment — Forecast to 2025”, prepared by the analytical company MarketsandMarkets, it is estimated that the market development focused on failure analysis amounted to USD 3.9 billion in 2020 and it is expected that in Within 5 years, it will reach the level of USD 5.9 billion. With the development of failure identification tools, their prediction and analysis has become easier, and the increased use of technology drives the market for their testing.

FitMech is one of the companies that contributes to the development of this market, and on the other hand, supports industrial enterprises in reducing the number of downtimes. The system created by a team of engineers allows you to control the amount of machine working time, determines the number of cycles and their length, analyzes the quality of work performed by specific machines, as well as the efficiency of employees on a specific shift. All this data is provided in real time.

At the same time, thanks to a simple application, operators can mark downtime on an ongoing basis, verify which of them occur most often or last the longest, control the time of planned downtime, such as retooling or machine calibration, as well as increase factory efficiency by eliminating the causes of failure.

Get in touch with our team and find out more about the opportunities we can offer your company!

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