According to the U.S. Bureau of Labor Statistics (BLS), there were 530,800 jobs for industrial machinery mechanics, machinery maintenance workers, and millwrights in 2023. The projected change in employment for 2023-2033 was 15%. This change was significantly higher than the 4% average growth rate for all occupations.
Skilled maintenance technicians reduce costly downtime in manufacturing facilities. Effective maintenance helps keep production running, minimizes disruptions, and maximizes efficiency. These factors elevate safety, productivity, and the bottom line.
Categories of Manufacturing Downtime
Three main categories of manufacturing downtime include:
Planned downtime
Planned downtime includes scheduled times to pause production for equipment servicing and maintenance:
- The technicians can predict and repair issues that could lead to unplanned downtime.
- The workspace remains safe and the equipment continues functioning.
- Regular maintenance and repairs extend the equipment’s longevity.
- These activities save time and money.
Unplanned downtime
Unplanned downtime occurs when manufacturing equipment unexpectedly fails:
- The production process might stop.
- Product quality can go down.
- Production delays, increased operational costs, and customer dissatisfaction could result.
- Employees might experience irregular work schedules, increased stress, and layoffs or relocation.
- The firm’s revenue and reputation can be impacted.
External downtime
External downtime occurs because of factors beyond the manufacturing firm’s control. Examples include:
- Supply chain issues
- Transportation delays
- Supplier emergencies
- Regulatory changes
- Natural disasters
The results of external downtime can include:
- Supply chain vulnerability
- Production delays
- Increased costs
- Customer dissatisfaction
- Revenue loss
Common Causes of Manufacturing Downtime
The common causes of manufacturing downtime include:
Hardware failure
Hardware failure can have multiple causes:
- Irregular maintenance
- Missed upgrades
- Power surges
- Equipment mishandling
- Overheating
- Wear and tear
- Dust and debris accumulation
- Aging equipment
Human error
Regular training and safety sessions involving best practices for handling manufacturing equipment help reduce human error. Investments in automated manufacturing equipment that require minimal human involvement can be beneficial.
Malicious sabotage
Vandalism, insider threats, and cyberattacks are intentional acts that impact manufacturing equipment and disrupt operations. These activities can be reduced by conducting employee background checks, continuously strengthening cybersecurity, and regularly monitoring the equipment and systems.
Power outages
The duration of downtime caused by power outages typically is longer than those caused by equipment failure or human error. Because these outages are beyond the manufacturing firm’s control, operations might not resume for hours.
Strategies to Reduce Manufacturing Downtime
The following strategies can reduce unplanned manufacturing downtime:
Schedule preventative maintenance
Preventative maintenance lets technicians proactively address potential issues to reduce their impact on production. These activities elevate safety, cost less than repairs, and extend the equipment’s lifespan.
Implement predictive maintenance
Predictive maintenance monitors manufacturing equipment to determine when maintenance is needed. Regular maintenance enhances equipment safety, improves productivity, and reduces operating costs.
Prioritize manufacturing processes
Schedule regular maintenance on equipment with the greatest impact on production output and customer deliverables. Examples include the cutting, drilling, and milling process, the assembly process, and the quality control and testing process.
Hire Skilled Maintenance Technicians in Manufacturing
Let Impact Staffing get to work finding your manufacturing firm candidates proficient in predictive maintenance, troubleshooting, and machine repairs. Connect with us to start the process today.
