Downtime is the greatest enemy of any business managing its own production lines. However, they’re not always caused by something dramatic happening somewhere within the manufacturing processes, but small issues that can build up over time. For that reason, here, we’re going to look at five of the most common sources of delays and loss on your manufacturing floor, and what you can do about them.
Image Source: Pexels – CC0 License
Poor Maintenance Schedules
A lack of routine maintenance is one of the easiest ways to make unexpected downtime almost guaranteed. When you skip or delay inspections, minor wear has the opportunity to grow. This can cause production defects to start appearing in your output before eventually leading to total equipment failure. Manufacturers should use planned maintenance calendars, digital tracking systems, and clear accountability to ensure every machine receives attention on time. Preventative maintenance is the key, and helps teams get better at spotting patterns of wear in the machines they operate.
Overheating Systems
Heat is one of the leading triggers of machines shutting down. Heat can build up around all those moving parts, with motors, compressors, boilers, and high-pressure systems being especially hot. This can become a problem if poor ventilation, blocked filters, or inadequate cooling systems mean there’s no way to effectively get rid of that heat. Routine airflow checks and cooling system maintenance, as well as keeping an eye out for overworked components, can help you ensure your systems stay cool.
Aging Infrastructure
If your production lines’ equipment, pipework, wiring, and the like have been in place for years, then the risk of failure is likely steadily growing with each passing day. Components such as industrial safety valves are designed to maintain the safety of the production line, but when they struggle ot keep up with modern production demands, it’s time to look for a replacement. Ensuring that they are inspected routinely can help you spot weak points in need of replacement or updates.
Lack Of Real-Time Monitoring
Many of the issues above can be prevented if you’re simply able to see them develop. Real-time monitoring of your machines and the data of their production can help you get a lot more visibility into when their production starts to suffer, which can give you an idea of when to step in. Sensors that look at pressure, temperature, vibration, and the like can also give you a more comprehensive view of machine health.
Inadequate Staff Training
Even the best equipment can have problems if your staff isn’t as well-trained as they should be. Your staff should be able to not only operate it, but also to inspect it, maintain it, and report issues when they start to appear. This isn’t a matter for individual staff members; it’s something that the leadership needs to invest in and set time aside for.
You might not be able to prevent 100% of shutdowns on your production line, but aiming to get as close to 100% as possible can ensure that you’re much more efficient and lose much less money than before.
Add Comment