Reducing downtime is essential for increasing productivity, cutting costs, and improving workplace safety. Downtime tracking software plays a vital role in identifying the causes of downtime and addressing them efficiently. By understanding why processes stop, manufacturers can take steps to minimize interruptions.

What is Downtime?

Downtime refers to any period when a production process is not operating. Downtime can be categorized as either planned or unplanned.

Planned Downtime

Planned downtime occurs when production schedules a break for maintenance activities such as inspections, cleaning, and parts replacement. This downtime is predictable and allows teams to organize resources, order parts, and schedule necessary tasks to complete during the downtime.

Unplanned Downtime

Unplanned downtime is unscheduled and happens due to unforeseen events like part failures, power outages, or material shortages. Unplanned downtime is unpredictable, making it a significant target for manufacturers aiming to reduce overall downtime.

Importance of Reducing Unplanned Downtime

Unplanned downtime is costly and hazardous. Because it is unpredictable, it’s difficult to prepare for every potential scenario. Delays in receiving parts or necessary personnel to address the issue can extend downtime, reducing production time and impacting profits.

Unplanned downtime also leads to wasted materials and unsellable products. Moreover, it can be associated with accidents or near-misses. The urgency to resolve the issue quickly often creates a stressful, reactive environment, which may compromise safety and efficiency.

Reducing unplanned downtime not only lowers operational costs but also minimizes risks to employee safety.

How to Reduce Downtime in Manufacturing

There are several strategies manufacturers can implement to reduce downtime. By tracking, monitoring, and analyzing downtime, businesses can take steps to minimize both planned and unplanned downtime.

1. Track Downtime

The first step in reducing downtime is to track it effectively. Understanding why processes are halting allows manufacturers to identify recurring problems and address them proactively.

Data to collect during downtime events includes:

• Duration of downtime
• Cause of downtime
• Product being processed at the time of downtime
• Affected process area
• Shift or crew involved
• Operator comments
• Environmental factors or safety concerns

While downtime can be tracked manually, automation helps ensure that all events are logged consistently. Downtime tracking software can simplify this process and help organize the collected data. Key features to consider when selecting downtime tracking software include:

• User-friendly interface
• Automatic event recording
• Integration with production data
• Analytics and event analysis tools

Automated systems, like dataPARC’s PARCview, offer comprehensive solutions that include downtime tracking alongside other manufacturing analytics tools.

2. Monitor Production

Real-time production monitoring is essential for identifying potential issues before they cause downtime. Displaying process trends at operator stations provides visibility into how the process is performing over time, enabling quick identification of variables that might be deviating from standard conditions.

Production dashboards and alarm systems can also help prevent downtime by alerting operators to any deviations that might lead to an interruption. This allows them to act promptly and resolve the issue before it escalates.

3. Create a Preventative Maintenance Schedule

Regular preventative maintenance during planned downtime can significantly reduce unplanned downtime. Scheduled maintenance ensures that necessary parts are replaced and that equipment remains in optimal working condition.

Preventative tasks include:

• Part replacements during scheduled downtime
• Regular lubrication and cleaning during production
• Inspection and maintenance scheduling

A well-organized preventative maintenance schedule can be tracked and automated using tools like PARCview’s Manual Data Entry (MDE). Automated reminders ensure that maintenance tasks are completed on time, reducing the likelihood of unexpected equipment failures.

4. Provide Operator Decision Support

When unplanned downtime does occur, minimizing its duration is key. Providing operators with decision-making tools, such as troubleshooting guides and process dashboards, enables them to identify and resolve the root cause more quickly.

Tools such as the 5-Why analysis, process dashboards, and trends can help operators investigate the cause of downtime and implement corrective actions more efficiently.

DataPARC’s Centerline display offers early fault detection and process deviation warnings, allowing operators to respond swiftly to issues and minimize downtime.

5. Perform DMAIC Analysis

The DMAIC (Define, Measure, Analyze, Improve, Control) methodology is a lean manufacturing tool that can be applied to reduce downtime by addressing both planned and unplanned causes. Here’s how to use it:

• Define: Establish a clear definition of downtime and identify potential reasons for it.
• Measure: Collect data on downtime events, including the cause, duration, and other contributing factors.
• Analyze: Use Pareto charts and other analysis tools to identify the most significant causes of downtime.
• Improve: Implement changes to prevent downtime from recurring and to reduce its duration when it occurs.
• Control: Continue monitoring and measuring downtime to ensure improvements are sustained over time.