Table of Contents:
Unplanned downtime refers to a sudden unexpected interruption that causes business operations and critical systems to come to a sharp and disorderly end. It comes out of the blue and one day that was productive can transform into an expensive crisis that no organization can afford to overlook.
No matter what is behind it, the reactive fix-it-breaks strategy is no longer a viable one in a market that requires 24/7 availability. Companies need to stop this gambling attitude to a strategic, evidence-based approach, which looks ahead to failures.
Cryotos CMMS is the key to this important shift, and the tool that will help you take the necessary step and shift your maintenance strategy to the proactive one. It uses real-time data to enable teams to stabilize operations and to get rid of unnecessary outages permanently.
To fix the issue, you will have to know its starting point. Although each facility is distinct, the perpetrators of downtime can be categorized into a few different groups.
Internal operational problems have been identified as the most common disruptions.
Although occurring less often, external threats are destructive. Extreme weather predictions may cause the tangible destruction of assets, whereas computer viruses and cyber-attacks may take the digital system as hostages, thus rendering the entire system out of commission.
The reactive approach is gambling. Making repairs after a failure ensures one has to do a lot of emergency repair work that is timelier and more expensive than simple preventative maintenance work. It is a cyclic process that will ensure that unnecessary downtime will occur again.
Most organizations fail to pay enough attention to the actual cost of an outage due to their consideration of only the more apparent repair expenses. You have to see the financial picture all the way through.
Begin by identifying the business functions that are critical to survival. Is it your main assembly line? Your Web-based transaction processing system? Understanding the value of the most important things can make you give a financial account of the price of every minute of time lost.
The effect can be measured with the following formula:
Downtime Cost = ((Lost Revenue per Hour + Lost Productivity per Hour) × Downtime Duration) + Recovery Costs
The numbers can be staggered. The cost in the industry such as manufacturing is easily more than PS50,000 per hour when you add idle labor, raw materials wasted, and the expensive cost of recovery of the complicated machines.
The harm inflicted by non-planned down time goes beyond the few hours of silence.
Reputation may be the hardest cost to cover. Constant outages will destroy customer confidence, create bad publicity, and ultimately mean loss of market share permanently.
It is not a matter of luck that a person is resilient; it is a matter of plan. This is what contemporary organizations are doing in their defense.
Instead of guessing, use data. CBM is the real-time monitoring of such industrial sensors as vibration, temperature, and pressure. This helps you in noticing anomalies such as a hot motor and correcting it before it gets to a shutdown.
Through analysis of data and past trends, you will be able to know when a machine will fail and maintain it in advance. This is to make sure that the downtime is at your own will, not that of the machine.
Failure Reporting, Analysis, and Corrective Action System (FRACAS) Implementation of the FRACAS methodology is one of the ways to detect the root causes in a systematic manner. It converts any failure to a lesson to enhance reliability in the future.
Cryotos CMMS helps to transition to resilience and convert scattered data on maintenance to actionable, proactive knowledge. It allows your team to be ahead of failure and provide operational excellence 24 hours a day.
Cryotos will be easily integrated with the IIoT sensors to offer 24/7/365 control over asset health at any time or place. You also get a single pane of glass into your whole operation, and you get to remove the blind spots.
Speed is critical. Work orders or alerts may be automatically activated by the cryotos when certain thresholds are met (e.g. a sharp rise in temperature). Such automation makes sure that the appropriate technician is informed as soon as possible, and the period of response is almost zero.
The use of Cryotos CMMS as an active measure produces effective outcomes. Maintaining cost can be cut by 25-30 and breakdowns can be completely eradicated by converting maintenance to a competitive asset and turning it into cost center.
Cryotos also assists in getting your systems back online within a shorter time in case of problems, since it allows maintaining a clear, convenient inventory of all hardware and software resources in your systems- an important piece in any successful recovery strategy.
Sudden failure may not be avoidable in the industrial environment, but its effect is one that can be handled completely. Through the appropriate recovery plans and maintenance software, any disaster has the ability to minimize a small inconvenience.
Days of inflexible calendar time schedules have passed. Businesses that want to flourish should abandon wasteful operations and adopt the use of data-driven and condition-based maintenance.
Ready to quit paying downtime? Learn how Cryotos can be used with your critical systems to automate your maintenance and to safeguard your assets.
