Unplanned Downtime: Part 7 – How Constant Breakdowns Lead to Spiraling Maintenance Costs

Unplanned downtime is a formidable challenge in the manufacturing industry, leading to substantial increases in maintenance costs.

These costs are not limited to the immediate expenses associated with repairs and parts; they extend to a range of secondary symptoms that can disrupt productivity and efficiency on the shop floor.

The frequent and unpredictable nature of unplanned downtime forces companies into reactive maintenance modes, where the focus shifts from proactive improvements to emergency fixes.

This shift in focus often results in overlooked preventive measures and contributes to recurring equipment failures and escalating costs.

One less common example of a secondary symptom linked to increased maintenance costs due to unplanned downtime is the careless neglect of auxiliary systems. When primary production equipment fails, the urgency to get the main line back up and running often leads to the postponement or complete oversight of maintenance for secondary systems like HVAC, conveyor belts, or even safety monitoring devices. This neglect can lead to compounded failures, where an initial equipment breakdown triggers subsequent issues in auxiliary systems, further driving up maintenance costs and downtime.

Understanding how unplanned downtime inflates maintenance costs is crucial for manufacturing leaders seeking to optimize operations. Addressing these issues requires a comprehensive approach that includes investing in preventive and predictive maintenance, fostering a culture of accountability and continuous improvement, and ensuring robust support systems are in place to mitigate the cascading effects of downtime. In this part of our Unplanned Downtime Mastery Series, we explore the top 10 ways unplanned downtime leads to increased maintenance costs and offer practical strategies to mitigate these impacts, helping you maintain a more efficient and cost-effective manufacturing operation.

1 Excessive Vibration Causing Component Misalignment:

Excessive vibration is a common aftermath of unplanned downtime. When machines are stopped and restarted abruptly, they often experience vibrations that can cause component misalignment. Misaligned components lead to uneven wear and tear, reducing the lifespan of parts and requiring frequent adjustments.

Mitigation: Implementing a predictive maintenance program that uses vibration analysis can help detect misalignments early. Regularly scheduled maintenance checks and alignment tools can ensure components remain in optimal positions, minimizing the impact of vibration-induced misalignments.

2 Overheating of Machinery Due to Sudden Stops and Starts:

Abrupt stops and starts increasing the risk of overheating machinery. Overheating can degrade machine components faster, leading to increased maintenance needs and unexpected failures.

Mitigation: Installing thermal sensors and monitoring systems can provide real-time data on machinery temperature. Implementing controlled shutdown and startup procedures can also reduce thermal stress, preserving the integrity of machine components.

3 Frequent Recalibration Needs:

Machines often require recalibration after unplanned downtime. Recalibration is time-consuming and diverts resources away from production, negatively impacting productivity.

Mitigation: Automating calibration processes where possible can reduce the frequency and duration of recalibrations. Regular maintenance schedules and advanced diagnostic tools can also ensure machines remain calibrated, even after unplanned stops.

4 Accelerated Lubricant Degradation:

Frequent starts and stops accelerate the lubricant’s degradation, causing increased friction and wear on components. This necessitates more frequent lubricant changes and increases maintenance costs.

Mitigation: Switching to high-quality, high-temperature-resistant lubricants can extend the intervals between changes. Implementing a lubricant analysis program can help predict when changes are needed, preventing premature degradation.

5 Increased Frequency of Part Replacements:

Unplanned downtime often leads to a higher frequency of part replacements. The repeated stress from stopping and starting machinery accelerates wear on critical components.

Mitigation: Adopting a condition-based monitoring system can help predict part failures before they occur. Stocking high-quality, durable parts and scheduling regular maintenance can also reduce the frequency of replacements.

6 Frequent Failures of Safety Interlocks:

Safety interlocks, designed to protect both machines and operators, can fail more frequently due to the irregular operation caused by unplanned downtime. This not only increases maintenance costs but also poses safety risks.

Mitigation: Routine testing and maintenance of safety interlocks can ensure they function correctly when needed. Investing in high-quality, robust interlock systems can also reduce the likelihood of frequent failures.

7 Higher Rates of Hydraulic Fluid Contamination:

Hydraulic systems are susceptible to contamination when machines are stopped and started unpredictably. Contaminants can cause significant damage to hydraulic components, increasing maintenance costs.

Mitigation: Implementing stringent filtration systems and regularly monitoring hydraulic fluid quality can prevent contamination. Scheduled maintenance and fluid replacement programs can also mitigate the risks associated with hydraulic fluid contamination.

8 Strain on Cooling Systems:

Cooling systems are designed to operate within specific parameters. Unplanned downtime causes these systems to work harder to maintain optimal temperatures, leading to increased wear and higher maintenance costs.

Mitigation: Regular cooling system maintenance, including cleaning and replacing filters, can ensure they operate efficiently. Upgrading to more robust cooling systems can also help manage the increased strain from unplanned downtime.

9 Corrosion Due to Inconsistent Use:

Inconsistent use of machinery can lead to corrosion, particularly in components exposed to varying environmental conditions. Corrosion increases maintenance costs and can lead to unexpected failures.

Mitigation: Applying anti-corrosion coatings and conducting regular inspections can prevent and detect early signs of corrosion. Ensuring machines are operated within their designed parameters and maintaining a controlled environment can also reduce corrosion risks.

10 Increased Strain on Diagnostic Equipment:

Frequent unplanned downtime places additional strain on diagnostic equipment as it is used more frequently to troubleshoot and resolve issues. This wears out diagnostic tools faster and increases the time and cost of maintenance.

Mitigation: Investing in high-quality, durable diagnostic equipment that can withstand frequent use. Regular calibration and maintenance of diagnostic tools can ensure they remain accurate and effective, reducing the overall strain on these essential pieces of equipment.

Conclusion for Manufacturing Leadership

Increased maintenance costs due to unplanned downtime can severely impact a manufacturing operation’s productivity. When machinery unexpectedly breaks down, the immediate financial hit is only part of the problem. The secondary symptoms—excessive vibration causing component misalignment, overheating due to sudden stops and starts, frequent recalibrations, accelerated lubricant degradation, and increased frequency of part replacements—further compound the issue.

These secondary effects lead to more frequent and intensive maintenance activities, draining time and resources that could be better spent on productive tasks.

Addressing these secondary symptoms is crucial for mitigating maintenance costs and enhancing efficiency. Implementing predictive maintenance allows for the early detection of potential issues, enabling proactive rather than reactive repairs. This approach reduces the frequency of unplanned downtime and extends the lifespan of equipment. Investing in high-quality components ensures that machines operate more reliably and withstand the stresses of regular use. Furthermore, adhering to regular maintenance schedules helps maintain machinery in optimal condition, preventing minor issues from escalating into significant failures.

How POWERS Can Help

At POWERS, we specialize in enhancing manufacturing productivity through tailored, results-based management consulting. Our unique approach, ‘Operationalizing Your Culture,’ aligns organizational culture with behaviors and skills that drive higher productivity and efficiency. Here’s how we can assist:

Predictive Maintenance Programs: Implement advanced predictive maintenance systems to identify potential issues before they become significant problems.
Quality Component Investments: Advise on the best quality components and materials to reduce the frequency of part replacements and maintenance needs.
Regular Maintenance Scheduling: Develop and implement comprehensive maintenance schedules to ensure machinery is always in optimal working condition.
Advanced Diagnostic Tools: Provide access to high-quality diagnostic tools and training to ensure accurate and effective troubleshooting.
Training and Development: Offer training programs for your team to enhance their skills in maintenance and troubleshooting.

By partnering with POWERS, you can transform unplanned downtime into a manageable challenge, leading to sustained productivity improvements and measurable ROI. Our hands-on approach ensures that you implement practical solutions and build a continuous improvement and operational excellence culture.

For more information on how POWERS can help you reduce maintenance costs and improve productivity, contact us today! Together, we can operationalize your culture to achieve higher productivity and efficiency.