Downtime in manufacturing refers to a period when a production line or machine is not operational due to maintenance, repairs, or other issues. This can result in decreased productivity, higher costs, and missed production targets. It is estimated that manufacturers in the US alone face losses of approximately $1 trillion per year due to downtime. Unplanned downtime is primarily caused by human error and inadequate maintenance.
To minimize downtime, manufacturers are adopting digital technology to transform their frontline operations and establish a comprehensive preventive maintenance strategy.
Reducing Downtime through a Connected Frontline Operations Platform
Manufacturers often implement Total Productive Maintenance (TPM) as part of a broader preventive maintenance approach. TPM is a strategy commonly used in manufacturing and production operations to enhance equipment effectiveness and reliability, thereby increasing productivity and reducing downtime.
Total productive maintenance aims to reduce workplace losses by assigning basic maintenance responsibilities to the primary equipment users, namely the machine operators. This preventive practice consists of “8 pillars” that improve equipment reliability and enhance worker productivity:
One of the key pillars in this framework is Autonomous Maintenance. Autonomous maintenance, a technique within TPM, empowers operators and frontline employees to take care of their own equipment and work areas. This includes activities like cleaning and safety checks. By involving employees in equipment maintenance, it fosters a sense of ownership and understanding of how their actions impact productivity and quality. It also promotes improved communication and teamwork, leading to increased engagement.
This is where frontline operations platforms come into play.
Connected frontline operations platforms are digital software tools that standardize and enhance the way operators perform maintenance tasks. They improve communication, training, collaboration, guidance, and support for operators.
Reducing Machine Downtime with Augmentir’s Connected Worker Solution
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The Crucial Role of a Connected Workforce in Reducing Downtime
Factory workers significantly influence downtime in manufacturing. Mistakes made by operators, suboptimal scheduling, and communication gaps all contribute to downtime in frontline operations. Factory workers can impact downtime in various ways:
Improper operation or maintenance: Insufficient training on equipment operation and maintenance can lead to mistakes and noncompliance with procedures. Modern connected worker tools, such as Augmentir’s connected worker solution, streamline training and digitize skills tracking to ensure that qualified individuals are assigned to tasks.
Safety incidents: Failure to follow safety procedures can cause accidents that result in downtime. Digitizing safety procedures ensures that workers adhere to the correct steps and protocols before conducting maintenance routines.
Human error: Mistakes made by workers, such as improper equipment setup or failure to recognize maintenance needs, can lead to downtime. Thoroughly training employees on equipment operation and maintenance helps minimize downtime caused by human error.
Quality issues: Production of substandard products can result in downtime for rework or disposal. Maintaining high-quality standards and training workers accordingly can minimize downtime associated with quality issues.
Lack of effective communication: Clear and efficient communication channels help promptly identify and address issues. Frontline communication tools like Augmentir improve communication and digitally record problems for better root cause analysis. Identifying the underlying causes of downtime enables manufacturers to prevent similar issues in the future.
High turnover rate: Frequent turnover leads to a lack of experienced workers, resulting in downtime during the training of new employees. Although preventing high turnover is challenging, measures can be taken to expedite training for new hires and create a more engaged and empowered workforce. Augmentir’s connected worker solution, for example, accelerates onboarding and provides a skills management framework to ensure workers excel in their roles.