Performance Management Series: Reducing Downtime Through Manufacturing Efficiency

This blog is a part of our performance management series for manufacturers. This series focuses on increasing manufacturing efficiency through optimized processes, equipment effectiveness, and the topic we will discuss today is reduced downtime. In this blog, the third topic of the series, let's discuss the impact of downtime and formulate effective measures to mitigate or completely eradicate this issue, thereby enhancing overall manufacturing efficiency.

Why is downtime important?

Reducing downtime, any unexpected halt in production, is important for manufacturers who need to do more with less—less labor, less margin, and less resources. Though purchasing the latest cutting-edge machines can make a manufacturer more competitive, the investments can often be several millions of dollars that manufacturers just don't have. For a portion of that money, cost-cutting measures can be found in reducing machine downtime. Reducing downtime can improve capacity, floor layout, and quality of parts produced.

Tracking downtime errors minimizes downtime across various categories, including maintenance, bias, and human error, by declassifying common errors so manufacturers understand where they come from before they occur. These collective improvements result in increased capacity across the facility. Understanding downtime can also mitigate operator errors, eliminate biases, enhance training, and elevate overall skillsets and labor utilization across the facility.

Additionally, downtime may stem from general wear and tear on equipment. Finding solutions to this type of downtime can lead to an uptake in quality assurance from sourcing improved quality raw materials from vendors, enhancing maintenance response or preventive maintenance programs, or refining inspection processes through process improvement initiatives.

How downtime software can help

Downtime tracking software can gather and standardize machine data and collect additional contextual data from operators via tablets stationed at each machine, providing manufacturers with precise downtime data and insights into the underlying causes. It allows for timely identification of machines falling behind production targets or experiencing downtime, facilitating prompt corrective actions and fostering accountability among shop floor employees.

By capturing the primary reasons for downtime, manufacturers can prioritize continuous improvement efforts and provide insights into shift performance, individual machine issues, and challenging jobs.

Using Alora’s Downtime Dashboard to minimize downtime

Alora is ECI’s machine monitoring platform. The Downtime Dashboard collects manufacturing data, comprehending the nuances in shop floor operations and machine activities, and tailors information to meet the unique requirements of individual users. Its centralized platform is capable of seamlessly connecting and analyzing data from ERP systems and machines in real-time.

The Machine Downtime Dashboard offers insights into machine downtime, whether scheduled or unscheduled, within a user-defined timeframe. This enables users to discern when and why machines are inactive and subsequently delve deeper to identify root causes.

Achieving consensus on data interpretation is often challenging, but this dashboard fosters alignment by ensuring everyone focuses on the same dataset, thereby facilitating quicker and more effective problem resolution. It provides manufacturers with real-time assessment of equipment health, empowering operators and managers to shift away from reactive maintenance practices, ultimately saving time and maintenance costs.

Contact us today for a demonstration.