Unplanned downtime in manufacturing is a costly nightmare. When machines unexpectedly stop, production halts, and costs quickly skyrocket. In fact, the cost of downtime can reach as high as £14,200 per hour for some manufacturers. To stay competitive, reducing unplanned downtime is crucial. At AssetMinder, we’ve developed a 5-step process that helps manufacturers minimise operational disruptions and keep production lines moving.
At AssetMinder, we’ve perfected a 5-step process to accelerate your journey to Predictive Maintenance while keeping disruptions to a minimum. Here’s how you can start reducing unplanned downtime and maximise operational efficiency.
Step 1: Identify High-Energy and Critical Assets
Not all machines are created equal—some are the backbone of your operations, while others drain more energy than you realise. Start by identifying your high-energy and critical assets, those that are both energy-intensive and crucial to your production line. These are typically the machines that, if they fail, can cause the most disruption.
Why This Matters:
- Targeted Maintenance: Focus your resources where they matter most.
- Energy Efficiency Gains: High-energy equipment is often the first place to find cost-saving opportunities.
- Reduced Downtime: By monitoring critical machines, you catch issues before they cause unexpected stops.
Pro Tip: Collaborate with your operations team to understand which assets are most critical and have the highest energy consumption. This cross-functional approach ensures nothing gets overlooked.
Step 2: Install Sensors and Monitoring Points
Once you’ve identified the key assets, it’s time to install sensors and monitoring points. At AssetMinder, we typically deploy:
- Vibration and Oil Quality Sensors for machine health.
- Electricity, Gas, and Water Meters for energy monitoring.
Why This Matters:
- Real-Time Insights: Continuous monitoring allows you to understand your equipment’s health in real time.
- Predictive Analytics: By collecting data on vibration and oil quality, you can predict failures before they happen.
- Energy Savings: Monitoring energy usage highlights inefficiencies and potential cost-saving measures.
Pro Tip: Start small by piloting the sensors on a few high-impact assets. Demonstrate the ROI and then scale up gradually across the facility.
Step 3: Integrate Data into a Single Dashboard
Data silos kill productivity. Integrate all the information gathered from your sensors into a single dashboard. This is where AssetMinder’s solutions shine, providing:
- Total Visibility: See the health of every asset across multiple locations in real time.
- Centralised Monitoring: Streamline operations by giving your team one unified view.
Why This Matters:
- Faster Decision Making: With all data in one place, you can make informed maintenance decisions quickly.
- Proactive Maintenance: Dashboards enable you to see trends over time, allowing for proactive maintenance scheduling.
Pro Tip: Make the dashboard accessible to your team on mobile devices. Real-time visibility isn’t just for the office—it’s needed on the shop floor too.
Step 4: Set Thresholds and Alerts
With your data integrated, it’s time to set thresholds and alerts. Establish parameters for normal and abnormal performance. When a metric crosses its threshold, an alert is triggered, allowing your team to intervene before a breakdown occurs.
Why This Matters:
- Minimise Unplanned Downtime: Real-time alerts enable your team to respond to potential failures before they escalate.
- Prevent Catastrophic Failures: Catching issues early reduces the risk of major equipment damage.
- Improved Safety: Alerts for abnormal conditions like overheating or excessive vibration can prevent hazardous situations.
Pro Tip: Regularly review and adjust thresholds as you gather more data. The more historical data you have, the more accurate your alert system becomes.
Step 5: Use Insights to Guide Maintenance and Interventions
This is where Predictive Maintenance truly comes to life. Use the insights gained from continuous monitoring to guide your maintenance strategy. With AssetMinder’s advanced analytics:
- Schedule Maintenance Efficiently: Plan interventions during non-peak hours to minimise production disruption.
- Optimise Spare Parts Inventory: Understand failure patterns and maintain the right inventory levels.
- Improve Maintenance Effectiveness: Make data-driven decisions on whether to repair or replace components.
Why This Matters:
- Reduced Maintenance Costs: Predictive insights help you avoid unnecessary maintenance activities.
- Increased Equipment Lifespan: Timely interventions prevent excessive wear and tear.
- Operational Efficiency: Downtime is minimised, keeping production lines running smoothly.
Pro Tip: Create a feedback loop with your maintenance team. Use their insights and experiences to continually improve your Predictive Maintenance strategy.
Why Choose AssetMinder’s 5-Step Process?
Our approach isn’t just about deploying technology—it’s about integrating Predictive Maintenance into your operational DNA. By following these 5 steps, you:
- Reduce Unplanned Downtime by up to 30%.
- Lower Maintenance Costs by focusing on the assets that matter most.
- Boost Productivity by keeping machines running smoothly and efficiently.
Ready to Minimise Unplanned Downtime?
Predictive Maintenance isn’t a distant future—it’s here, and it’s transforming the way manufacturing plants operate. At AssetMinder, we’re dedicated to helping you accelerate your journey while minimising disruptions.
Are you ready to take the first step? Let’s start by identifying your high-energy and critical assets. Contact us today to learn how AssetMinder can revolutionise your maintenance approach.
By implementing this 5-step strategy enabled by AssetMinder Predict, you’re not just maintaining equipment—you’re building a smarter, more resilient manufacturing operation. And that’s how you stay ahead of the competition.
