Know how to lower machine downtime in factories

RipplesCMMS for reducing machine downtime in factories

10 tips to reduce machine breakdown in factories

Realtime tracking of machine downtime in factories

Track downtime. The first step to reducing machine downtime in factories is to understand where it’s coming from. Track downtime by machine, cause, and duration. This data will help you identify the areas where you need to focus your improvement efforts.

  • Focus on the constraint. Every manufacturing process has a constraint or bottleneck. This is the point in the process where production is slowed down the most. Focus your downtime reduction efforts on the constraint, as this will have the biggest impact on overall production. MTBR and MTBF ratios are available on the dashboard
  • Treat downtime as a KPI. RTLS dashboards provides a metric that is used to track progress towards a goal. When you treat downtime as a KPI, you are sending a message that it is an important issue that needs to be addressed.
  • Make downtime events visual. Create a downtime board or chart that shows the current status of all machines in the factory. This will help to raise awareness of downtime and make it easier to identify and address problems.
  • Empowering managers: The factory abnormality manager has a pivotal role to play when it comes to problem-solving. Enabling him with a CMMS system will make the difference.
  • Separate quick fixes and 100-year fixes. When you are analyzing downtime data, it is important to distinguish between problems that can be fixed quickly and easily and problems that require a more long-term solution. Focus on fixing the quick fixes first, as this will have the biggest impact on reducing downtime in the short term.
  • Implement a preventive maintenance program. Preventive maintenance is the practice of performing routine maintenance on equipment to prevent breakdowns. A good preventive maintenance software will help to identify and address potential problems before they cause a machine to break down.

Ways of reducing machine downtime in factories

  • Invest in monitoring. Condition monitoring is the use of RTLS devices with temperature humidity and acceleration and other technologies to track the usage of production equipment.
  • Train your operators. Properly trained operators are less likely to misuse or abuse equipment, which can lead to breakdowns. Training on how to use the panic button should cover normal operating procedures, troubleshooting procedures, and safety procedures.
  • Empower your operators. Give your abnormality manager and operators the authority to stop the line if they see a potential problem and get help from the animal manager. This will help to prevent small problems from turning into big breakdowns.
  • Use technology to your advantage. There are several technologies that can help you reduce downtime, such as computerized maintenance management systems (RipplesCMMS) and machine learning. A CMMS can help you to track and schedule preventive maintenance tasks, while machine learning can be used to identify patterns in downtime data that can help you predict and prevent future breakdowns.

Read this machine breakdown tracking case study in an automotive component factory.

author avatar
Mr Srihari Acharya is head of Ripples IoT pte Ltd, RTLS solution sales in Bengaluru India. He brings over 6 years of experience and expertise in industrial automation solutions