Regularly scheduled on-site service and maintenance help detect and address issues before they lead to equipment failure. This proactive approach means staying ahead of issues instead of taking a reactive approach to maintenance. Preventative rather than reactive maintenance is the best way to approach maintenance in a manufacturing facility. It allows planned downtime instead of unplanned and costly downtime and reduces the cost of worn-out equipment and chain reaction failures.
Use Predictive Analytics
Technology has come a long way, which makes monitoring equipment health in real-time possible. This predictive analysis allows manufacturers to stay ahead of the curve and project when parts need to be serviced or replaced ahead of time.
Train and Upskill Workers
Well-trained employees are less likely to make errors and more capable of resolving issues quickly. Troubleshooting and quickly resolving issues before they escalate are highly sought-after skills. By providing advanced training in the latest equipment, technology, and best practices for maintenance and repair, facilities set up their workforce for success. This reduces downtime.
Establish Quick Troubleshooting Protocols
Set up standardized procedures for diagnosing and repairing equipment failures to minimize downtime. Having routine systems in place that are followed every time there is a specific type of issue eliminates the question of what needs to happen next. Keep troubleshooting protocols in an easily accessible location and provide regular training on them. It never hurts to do a mock workplace event to try the procedures out.
Ensure Proper Spare Parts Inventory
Keep essential spare parts in stock to enable quick repairs and prevent extended downtime. This is especially important for parts with a backlog when ordering or for longer shipping time. Risking downtime because you don’t have the right part is not a problem you want to have, especially when it could take weeks for a specific product to become available.
Optimize Supply Chain Management
As with having parts on hand, accurate demand forecasting is important so you know what parts or supplies you need to have on hand when. Instead of being reactive, stay ahead of business demand with projections and predictive analytics.
Automate Processes
Automating manual tasks reduces human error, speeds up production, and allows for faster problem detection. A CIP system effectively does this in consumable processing industries. So, what is Clean in Place? The system allows food and beverage processing facilities to thoroughly clean and sanitize the inside of processing equipment without manually taking it apart.
Conduct Root Cause Analysis (RCA)
RCA allows you to identify the cause of incidents and retroactively identify solutions to prevent those incidents from happening in the future. This is a proactive way to turn a negative into a positive by creating SOPs to ensure processes are followed moving forward that eliminate or reduce user error and increase routine maintenance measures.
Invest in Redundant Systems
Implementing backup systems is an instrumental way to maintain uptime in the case of system failure. Redundant systems include: cross-training employees, multiple process lines so there is always a backup, onhand spares, and secondary systems for energy, IT and communication. By proactively creating these systems, production can run efficiently.
Improve Communication and Collaboration
Communication between teams is essential for processes to run smoothly. From Slack to Teams, to Asana, or even email, communication channels allow everyone who needs to be in the know to stay abreast of evolving situations that impact a manufacturing facility’s overall health and uptime. Any delays, part problems, line issues, recalls, or safety issues can and should be communicated regularly and effectively through a standard communication channel everyone uses.
