Achieving world-class performance is our ultimate goal, aiming for less than 10% unplanned downtime. With three main production lines, we have seen improvements from our previous figures of 8%, 13%, and 9% in 2015. Taking into account the necessary 12-16 hours of planned downtime each week for maintenance, we ensure that any delays or issues are accurately accounted for as unplanned downtime. Our detailed trending of production parameters enables us to closely monitor and calculate unplanned downtime with precision. What should be our target for optimal performance?
Upon receiving the latest AMP newsletter in my inbox, I noticed the subject line was "[AMP] How Do You Accurately Track Down Time?" and included a discussion on the topic. Initially, I intended to respond with our proprietary "True Downtime Cost" (TDC) methodology, which can be found at http://downtimecentral.com/tdc.shtml. To my surprise, upon further exploration, I discovered that the focus was not on the "how-to" aspect but rather on defining what constitutes a world-class percentage. In my opinion, the ultimate aim should always be continuous improvement, regardless of varying perspectives on what defines today's benchmark for "world-class" performance.
Given the significant improvements made since 2015, I'd recommend focusing not just on minimizing downtime, but also maximizing the efficiency and productivity during uptime. If your unplanned downtime is already below 10%, it shows you're on the right track. Keep in mind that some level of downtime is unavoidable in any production process, especially when you prioritize regular maintenance, which is crucial for long-term productivity. Therefore, an optimal target could be to maintain a 5-7% unplanned downtime threshold while constantly working on process optimization to utilize your uptime effectively. Incremental improvements in both areas can have a profound impact on your overall performance.
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
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Answer: Unplanned downtime refers to any unexpected interruption in production that was not scheduled in advance, resulting in the halt of operations and loss of productivity.
Answer: Unplanned downtime can be calculated by tracking the actual time the production line is non-operational due to unexpected issues or delays, and subtracting any planned downtime for maintenance or other scheduled activities.
Answer: Implementing proactive maintenance schedules, conducting regular equipment inspections, investing in predictive maintenance technologies, training staff on troubleshooting techniques, and monitoring production parameters for early detection of issues can help reduce unplanned downtime.
Answer: Achieving less than 10% unplanned downtime can lead to increased productivity, improved efficiency, higher profitability, better customer satisfaction, and a competitive edge in the industry. It demonstrates reliability and consistency in meeting production targets.
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