Equipment downtime is inevitable in any operation or business. Downtime refers to how much time specific types of equipment are not operating. Halts in operation may be due to a regular maintenance schedule or an unexpected failure.
Tracking the downtime of equipment is very important because it can give you an idea of the health and readiness of your equipment. Equipment that experiences constant downtimes can be analyzed to determine the cause of the high downtime. If the equipment is old and constantly breaks down, you can decide to replace it with a new one.
High downtimes may signify that you implemented preventive maintenance haphazardly or that the equipment needs a replacement. A low equipment downtime indicates that all equipment is working at optimal levels. On average, equipment should be running at least at 90 percent availability.
Reasons to Track Downtime
● Streamline Processes
Planned downtime is the scheduled time when equipment is prepared, maintained, upgraded, or tested. Planned downtime is typically pre-determined and scheduled in advance. Meanwhile, unplanned downtime usually happens when an unexpected failure or breakdown happens. Unplanned downtime can happen at any time and may affect the operations of the company.
By tracking for both planned and unplanned downtime, you will determine the pattern and reliability of individual equipment. You can already predict which equipment needs parts, which equipment requires more maintenance, and which one is working correctly.
● Save Money
Unplanned downtime costs money. Your staff will still be paid even when the team is not working due to equipment repairs or equipment breakdown. On average, a factory loses five percent of its productivity due to downtime.
By consistently tracking downtime, you will know which equipment needs more thorough maintenance or replacement. Well-maintained equipment will have less downtime and a more efficient operation. Less downtime will mean more work done and good for the bottom line.
● Extend Asset Life Cycles
An asset is a resource with economic value. Equipment is a fixed asset that can bring economic value to the company. Tracking downtime can help extend life cycles because it can monitor if the equipment is overused. Assets driven to breakpoint will not last as long as those being adequately maintained. Implement planned downtime to ensure the equipment runs more efficiently and has an extended life cycle.
How to Get Started
● Make Preventive Maintenance Part of Your Schedule
Preventive maintenance is the systematic servicing and maintenance of equipment or facilities. Preventive maintenance aims to increase reliability, save money, and prevent downtime and failure. Preventative maintenance includes testing and replacing worn parts, diagnosing problems, and upgrading equipment or parts.
It also involves servicing the equipment according to the recommendations of its manufacturers, such as tightening, adjusting, and lubricating parts. Preventive maintenance can help track and eliminate downtime. Preventive maintenance should be part of your schedule.
It would be very beneficial to create a time-based maintenance schedule that integrates a monthly or annual maintenance timeline. This strategy outlines ideal times to inspect and clean equipment types so that they work efficiently.
Another type of preventive maintenance is usage-based maintenance, where assets are scheduled for downtime depending on the amount of time of usage. This tactic is usually implemented with equipment assigned manufacturer-recommended schedules based on the number of hours of operations.
Predictive maintenance would rely on built-in sensors and observations. Constant monitoring is required to see whether the equipment is still operating to its optimal level. It’s crucial to analyze vital information so the facilities can predict when the downtime may occur based on the previous pattern of the equipment.
● Implement a CMMS
A computerized maintenance management system (CMMS) is a computer application that assists facility managers and staff in scheduling maintenance, manage assets, and track work orders. It helps maximize the availability and utilization of equipment, machinery, vehicles, electronic equipment, and other company assets.
A CMMS contains a vast database of information about the asset, including maintenance schedules, status, maintenance history, work order, etc. The best way to track downtime is by using facilities maintenance software. It can collect vital data and analyze data on equipment downtime.
Stay Ahead of Downtimes
Unscheduled downtime due to the failure of equipment can be very costly to the company. By using CMMS software, you will schedule and track maintenance downtime reducing the risk of equipment failure. It can also provide an analysis of the status of the equipment, such as the overall equipment efficiency.
CMMS can track any asset’s downtime and provide real-time information to everyone, including the facilities manager and staff. It lessens equipment downtime and saves money since it also helps extend the life cycle of assets.