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7 Ways to Minimize Manufacturing Downtime

In a manufacturing, plant downtime eats out a lot of productivity and its reduction is a major concern of every manufacturing manager. Discover the top seven strategies to decrease machine downtime and increase the productivity and ROI of your manufacturing industry. To know more about machine downtime reduction and its proper tracking, visit: www.downtimecollectionsolutions.com<br>

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7 Ways to Minimize Manufacturing Downtime

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  1. 7 Ways to Minimize Manufacturing Downtime www.downtimecollectionsolutions.com

  2. All hell breaks loose when delivery deadlines are getting close and the plant is fighting with frequent manufacturing downtime. Profit’s not the only thing at stake. Your professional reputation and employee morale are on the line, too. Can downtime be fought without major changeover every time?

  3. Whileitmaynotbepossibleto entirelyeliminatedowntime, it ispossibletogreatlyreduce manufacturingdowntime. Downtimetracking, alongwith properunderstandingofthe rootcausesandsubsidiary issues, isanessentialpiece. Professionallyspeaking, manufacturingdowntime isamanager’sworst nightmare. Thescarier partisthatit’saregular phenomenon. Thegood news? 

  4. Machinery breakdown Thisisafairlycommonscenario, especiallyon shopfloorsofbusyindustrialunitsutilizingtheir fullpotentialandrunning3shiftsaday. New ordershavetobefilled, butitdoesn’tmakesense tokeepexpandingtheshoparea. Inthesecases, thebestsolutionistomaximizetheperformance ofexistingmachinery.

  5. Theracetoincreaseproductioncanoftenleadto neglectingroutinemaintenancelikeoiling, greasingand dustingmachines. Smallandsimplecheckslikelooking foroverheatingandadequateproductioncangreatly helpindowntimetracking. However, thesechecksaren’t theresponsibilityoftheoperatoralone. Workingwitha machinedayinanddayoutcanmakeiteasytomissthe littlesignsthatit’sabouttobreakdown. Thisisonetask thatshouldbeexternallymanagedbythepeoplewho aregoingtogethurtbyitthemost, themanagement.

  6. Skilled, trained and updated employees Everyestablishmentevaluates andinterviewsnewrecruitsat alllevels. Employeescome, and theloyalandhardworkingones remainwiththecompanyfor thelonghaul. Butisitthesame withmachines? Inthisageof competitivenessitisn’treally possibletomaintainnecessary speedwithoutdatedmachines. So, themanagementdoesthe rightthingbyupgradingtonew machinesasnecessary.

  7. What about the employees?  Weretheyretrainedandupgradedwith samesincerity? Thisisafactorthatisvery beneficialinreducingmanufacturing downtime. Downtimemaybearesultof manyfactorslikeprofessionalinefficiency duetolackofpropertrainingoreven stubbornnessoftheemployeestoupdate theirskills. Manytimes, senioremployees don’tshowthesamedrivetolearnnew thingsbecauseofego, overconfidenceor evensheerlaziness. It’simportantthat regular, mandatorytrainingsessionsare scheduledandemployeesareevaluated relativetothemachinestheyregularlyuse. Downtimetrackinghelpsinfindingthe potentialcandidates, showinginefficiency sothatemployeescanberetrained.

  8. Efficient manufacturing processes Assemblylineproductionsystems haveproventobeabigboontothe industrializedmanufacturing processes. Thesesystemstendtomake apersonspecializedtodoaparticular jobbycontinuousrepetition. But, a chainisonlyasstrongasitsweakest link. Whatifthereisasnaginone process, oritisn’tworkingatitsfull potential?  Itwillputextraburdenonboththeequipmentand operatorsofsubsequentprocesses, leadingtoagreater dangerofmanufacturingdowntime.

  9. Downtimetracking helpsoneexamine thesesnagsand bottlenecksin detail. Thefaulty processcanbe trackedand mendedbeforethe greaterdamageis done, leadingtoa streamlinedversion oftheentire process.

  10. Advance spares and tools Businessisallaboutprofit. A pennysavedisapennyearned, sotherewillalwaysbeatussle betweenrequirementand procurement. Althoughitmay seemwisetoonlykeep necessarypartsonhand, cana standardshopfloorreally predictwhichbreakdownswill happen? Thisiswheredowntimetrackingplaysa majorrole. Ithelpsyoutounderstandthe regularcausesofmechanicalbreakdowns. Ithelpsyoutoanalyzeparticularspare partsthatmalfunction, accordingtothe frequencyofoccurrences. Thiswillnot onlyhelpinkeepingthesparesand knowledgehandy, butalsohelpeliminate idleemployeetimewhilepartsarebeing procured.

  11. User feedback and employee contribution Mostmanagementdecisions comefromthetopdown, basedonfactspresentedby peoplewhoaren’tontheshop floor. Althoughit’sagoodidea intheory, therealityonthe groundoftendiffersfromthe scenariomanagementthinks theysee. Whenprofessionalsrequestnewmachineryor anupgrade, theyoftentakeitforgrantedthat productionprojectionsareforideal conditions, whichdon’ttypicallyexist. Hence achievableoutputisusuallylessthanthe pitchedoutput. Variousfactorslike environmentalconditions, easeofoperation, andcomplicatedfunctioningcanall contribute.

  12. Itisveryimportanttogatheruserfeedbacktofully understandamachine’sefficiencyandhandling. The issuescouldrangefrommechanicalhindrancesto handlingdifficultiesorvulnerabilityofamachineryto functioninaparticularenvironment. Issuecanonlybe solvedproperlyifaproperapproachisappliedto measuretheoutputandthepotentialhindrances. If employeesarekeptintheloop, notonlycanreal-time problemscouldbesolved, buttheyalsofeelencouraged andmotivatedtocurbmanufacturingdowntime.

  13. Careful tracking of downtime Evenifyou’vebeentakingalltherightstepstoreduce manufacturingdowntimeinyourplant, therecouldstillbesome solutionsthatarejustoutofreach. Evenwhenyouarewell- preparedfordowntime, youcouldstillfindmachinesnotrunning becauseemployeesarenotstartingontime. Suchproblemscan onlybeeffectivelysolvedifyourdowntimetrackingprecisely pinpointstheissues. Manualdowntimetrackingalwaysleavespace forerrorsofjudgmentbasedonsubjectiveanalysisanddelays.

  14. Careful tracking of downtime Today, manydowntime trackingsoftwareoptionsare availablethatwillcatertothis exactrequirementprecisely andsimply. Thedowntime trackingsoftwareprioritizes informationandindicatesin realtimewhichmachine needsrepairand maintenance.  Thesetoolsalsoassessthepotentialproductivity killersthatstandinthewayofyourfacility’s long-termproductiongoals. Forachieving ‘world class’ to ‘perfect’ overallequipmentefficiency goals, downtimetrackingcouldbeaperfect solution. Itwillhelpyounotonlyinfindingthe breakdownsassoonastheyoccur, butalsoin understandthereasonsforfrequentlyrecurring problems. Itwillprovideyouwiththeadvantage oftakingpreemptivemeasures. 

  15. Holistic approach Downtimetrackinghelpstokeep thesystemoiledandgreasedforthe greatergoodofboththepeopleand thecompany. Theworkenvironmentinbig industrialunitscanbefrustrating andoverwhelming. It’shuman naturetokeeptryingformore, especiallywhenthereare deadlinestomeet. Machines, as wellasemployees, tendtobreak downorreachtheirboilingpoint whenthingsgetbusy. Useaholistic approachforbothemployeesand machinestohelpavoidextra pressure. Ifthesystemisperfectly oiledandgreased, therearefar fewerchancesofdeveloping friction. Itkeepsthecommunicationchannel open, showsthepossiblefactors causingthedowntimeorsnags, and avoidstheunnecessary “blame game,” whichisafairlycommon scenarioinhigh-pressurework environments. Creatingacultureofaccountability helpspromoteaworkenvironment thatiscordial, healthyand supportive. www.downtimecollectionsolutions.com

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