How to Reduce Downtime in Manufacturing

In manufacturing, every minute counts. You want to maximize profit and minimize time you’re not earning money, and when production halts, revenue stops—but costs don’t.

The average cost of downtime? $260,000 per hour.

Unplanned downtime isn’t just inconvenient—it’s one of the most expensive problems manufacturers face. So how do you become one of those companies that has such a good handle on it that downtime becomes a rare event?

The Best Ways to Monitor & Reduce Machine & Factory Downtime

Guessing downtime is costly—so tracking it is essential.

Relying on estimates instead of actual data can lead to misinformed decisions and expensive oversights. A data-driven approach to monitoring downtime gives you the clarity and control needed to improve efficiency and protect your bottom line.

Many companies rely on tracking tools and technology to catch minor issues before they escalate into major problems, including:

• Specialized manufacturing software
• Supervisory control and data acquisition (SCADA)
• Machine sensors
• Downtime tracking dashboards

Causes of Downtime in Manufacturing

Downtime happens for a lot of reasons, but a few stand out as the most common. Equipment failure is a big one. When machines break down from wear and tear or lack of maintenance, production stops, causing delays, missed deadlines, and lost revenue.

Human error is another frequent cause. Mistakes made on the line, whether from miscommunication, poor training, or skipped steps, can bring operations to an end. Even small errors can create big problems.

Other causes include software issues, unplanned maintenance, and supply chain delays. Each of these can interrupt workflows and cause slowdowns.

Discover how to prevent downtime in manufacturing due to cyberattacks like ransomware by watching our on-demand webinar: Keys to Cybersecurity in Manufacturing: Prevent Downtime, Stop Threats.