Machine downtime or even a shutdown is still a worst-case scenario in manufacturing. It is therefore obvious that maintenance is one of the elementary adjusting screws for making production more efficient and reducing costs. Unplanned plant downtimes are still one of the main cost drivers, as they are often detected too late. In addition, there is almost always a lack of defect descriptions that show the problem in a dedicated way. As a result, additional time and capacity must be spent looking for the cause of the problem – because until this is known, neither the right measures can be determined nor the right maintenance contact alerted. By identifying and eliminating unplanned plant shutdowns more quickly, daily production can be increased by an average of ten percent.
However, central plant monitoring does not only offer real added value in the event of a shutdown. Even without shutdowns, process deviations can be detected more quickly, for example in the case of creeping deterioration due to longer cycle times or slowly increasing energy consumption. The possibility of target/actual comparisons of relevant process values, such as piece counts, cycle times or energy values in real time, provide direct information about unwanted deviations.
Competitive advantage thanks to central plant monitoring
Unplanned plant shutdowns will always occur. However, reducing the frequency or mitigating the effects saves money.
A plant shutdown inevitably leads to production backlogs and a reduction in the number of pieces at the end of the day. These can often only be countered with overtime or the provision of reserve capacity. These costs often add up to a staggering amount. All the more reason to keep the number of plant shutdowns as low as possible – and in the worst-case scenario – at least to act efficiently and save costs.
Companies that implement the following four parameters will be better prepared and create a true competitive advantage: