When the Machine Stops: The Real Cost of Industrial Downtime

Downtime Costs More Than Lost Production

The most obvious cost of equipment failure is lost production. But there are often additional costs that aren’t immediately visible.

An unexpected shutdown can result in:

• Overtime for maintenance and production personnel
• Expedited parts and materials
• Emergency contractor costs
• Delayed shipments
• Lost production capacity
• Additional wear on other equipment
• Disruptions to scheduled production

Even a relatively short equipment failure can create a much larger impact when it occurs at the wrong time.

Small Problems Can Become Big Problems

Industrial equipment often provides warning signs before a major failure occurs.

Unusual vibration, excessive noise, overheating, leaks, worn components or declining performance can all indicate that something needs attention.

The challenge is that production demands don’t always make it easy to stop and investigate.

It’s tempting to keep equipment running as long as it is still producing.

But postponing a repair doesn’t necessarily make the problem go away. In some cases, it allows a relatively manageable issue to develop into a much more expensive repair.

Planned Maintenance Gives You More Control

One of the advantages of planned maintenance is the ability to address problems on your schedule rather than the equipment’s schedule.

If a machine needs repair, alignment, component replacement or modification, the work can potentially be coordinated with a scheduled shutdown or slower production period.

That gives maintenance and engineering teams time to:

• Identify the scope of work
• Order necessary parts and materials
• Coordinate contractors
• Prepare the work area
• Plan around production requirements
• Establish a realistic timeline

Planned downtime is still downtime. But it is downtime you can prepare for.

Alignment and Installation Matter

Preventing downtime isn’t limited to repairing equipment after problems develop.

Proper installation and alignment can also play an important role in long-term equipment reliability.

Misalignment can contribute to vibration, premature component wear and other mechanical problems. When new equipment is installed or existing equipment is relocated, making sure everything is properly positioned and aligned is an important part of the process.

This is where experienced millwright services can make a difference.

Don’t Forget the Equipment That Keeps Material Moving

Conveyor systems are another area where a small problem can quickly affect production.

Belts, rollers, bearings, drives and other components should be inspected regularly for signs of wear or developing problems.

Because conveyors are often connected to multiple stages of a production process, one failure can have a much larger impact than the individual component might suggest.

Regular inspection and maintenance can help identify problems before they result in an unexpected shutdown.

The Goal Isn’t Zero Downtime

Every manufacturing facility has downtime.

The goal isn’t necessarily to eliminate it completely.

The goal is to better control it, plan for it and reduce the amount of unexpected downtime that interrupts production.

That starts with understanding the condition of your equipment, addressing problems when they are identified and planning major work around your production schedule whenever possible.

At Northwest Installations, we work with manufacturers and industrial facilities on millwright services, equipment installation and relocation, precision alignment, industrial repair, fabrication and conveyor services.

When equipment needs attention, planning ahead can make all the difference.

If you have equipment that needs to be repaired, relocated, installed or evaluated, contact Northwest Installations to discuss your project.

Northwest Installations, Inc.
Millwright & Mechanical Services