Downtime is the scourge of manufacturing facilities worldwide. It causes thousands of headaches and costs businesses billions of dollars each year.
并不是所有的停机时间都是可以避免的，但大部分是可以避免的. 如果你想防止不必要的, 设备意外停机, here are six ways to reduce downtime in your production process and keep the flow of your facility under control.
Downtime is when a computer, robot, or piece of equipment is unavailable for use. Downtime is every manufacturing facility’s worst nightmare. It brings production to a screeching halt for an undetermined amount of time and can make a sizeable dent in a business’s bank account.
On average, downtime costs businesses $5,600 a minute and $336,000 per hour. And with most instances of downtime lasting hours and occasionally days, 这相当于每起事故造成数百万美元的损失. “哇，”你可能会想，“这是一个很大的数字. 停机时间如此昂贵?”
The three main reasons downtime is so costly is because it results in low or nonexistent production output, 减少员工生产力, 以及客户流失. 别忘了把维修费用也算进去!
The effects of downtime don’t happen all at once, either. Unplanned downtime has enduring effects that can haunt a facility for months or even years. 当客户因停机而感到不方便时, 他们可能会选择在其他地方做生意, which leads to revenue cuts that take a long time to fix.
You may have heard the terms “planned downtime” and “unplanned downtime” thrown around and wondered, “它们有什么区别??”
计划停机时间是有目的的. Businesses plan for this kind of downtime days, weeks, and sometimes even months in advance. Many businesses use planned downtime to perform maintenance, handle repairs, and implement changes. It doesn’t have nearly as devastating a financial impact as unplanned downtime because businesses get to choose the time and date it occurs and make accommodations to ensure financial losses are minimal.
然而，计划外的停机是意外的. 它突然而频繁地发生，没有任何预兆. 发生计划外停机时, managers have to call in professionals to pinpoint the root of the problems and determine how to fix them. In the meantime, it leaves workers with nothing to do but loiter around and wait. 也, 这让客户感到困惑, wondering why the company’s website stopped working or why they have to wait longer for their order. Everything is a chaotic mess—and that chaos comes with devastating effects.
停机时间并非完全可以避免. Sometimes, equipment 打破s, malfunctions, or shuts down for no good reason.
But most of the time, you can prevent downtime or at least minimize its financial impact. You can do this by taking precautionary and preventative actions. Here are six ways to reduce downtime in your production process.
你需要生产多少? You want to run your equipment quickly enough to meet your quotas, 但你不希望它运行得太快. The harder your equipment works, the faster it wears down over time.
Setting production goals will make it easier to choose the right production speed and schedule maintenance for your facility. This, in turn, will help cut back on instances of unexpected downtime.
Preventative maintenance can dramatically reduce downtime in your production process. 随着时间的推移，所有的设备都会逐渐磨损, but by performing recurrent maintenance on your equipment, you can prevent that wear-and-tear from turning into machine failure.
但是你怎么知道多久需要维护一次呢? The manufacturer’s recommendations can give you a general idea, 但最终, the way you use your equipment determines how quickly it wears down over time. 详细记录口吃的频率, 打破, or fail and use it to create a personalized maintenance plan for your facility.
Is your equipment past its prime, outmoded, or on the decline? It may be time to let it retire in peace and hand down its role to newer, hardier machines.
旧机器在其全盛时期运转得很好. But after enduring a few years of hard and fast-paced work, they became worn-down and tired. They can’t keep up with the fancy technology of new machines anymore and are more prone to malfunctioning and 打破ing down—which, 当然, 导致停机时间.
Replacing old equipment with new equipment requires a substantial investment but can save your facility thousands to millions of dollars in the long run by keeping instances of downtime low.
Did you know that 70 percent of downtime comes from user error? 破坏设备的方法有上百种. 错误的按钮? 错误. 传送带上杂物太多? 错误. 没有正确的校准? 错误.
To err is to be human, so encountering mistakes every once in a while is inevitable. But untrained workers tend to make considerably more mistakes than trained ones.
Properly training your production line workers can reduce the number of mistakes they make and, 因此, 您的设施经历的停机时间.
You can also teach your workers how to perform basic maintenance tasks. 这种方式, they can lend a hand when downtime does occur and help get the production line back on track.
您的大多数过程是手动执行的吗? 自动化可以减少停机时间. 如何? 自动化机器比人类更不容易出错. 他们高效、持续地完成任务. 更少的错误意味着更少的错误和更少的停机时间.
Automation has other perks on top of downtime reduction. It reduces labor and material costs and enhances the quality of manufactured products.
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