In order to get a true picture of this, we need to identify where the real costs lie. So first things first…let’s separate planned downtime from unexpected downtime. Planned includes things like preventative maintenance, which can go a long way to help reduce the unexpected kind. The time spent on PM is usually seen as a simple cost of doing business and there is no downside to it. It’s the unexpected that needs more attention. So now that we’ve cleared that up, things should be much simpler, right? Not so fast.
There are a number of different costs wrapped in this package, and we need to be aware of all of them before we start looking for a solution that can show a return on investment by reducing these costs. We also need to have some realistic expectations of our capabilities. Let’s take a look at 3 possible paths:
- ELIMINATE – Forget about this one, it’s impossible. Unplanned downtime is a reality that will always exist. If it’s a machine, it’s going to break down unexpectedly (usually at the worst possible time).
- PREVENT – Step in front of the problem before it happens, a sound strategy. A good preventative maintenance program, followed regularly, can help to reduce a good deal of overall unexpected downtime, but it will only do so much.
- REDUCE – Again, preventative maintenance will help with this. But what else can be done to reduce the amount of time a machine spends down due to an unforeseen breakdown? In what other areas of expense is there room for improvement?
Reducing unexpected downtime is where our attention should be since it’s where we can see the biggest return for our efforts. In order to do that, we need to have a clear picture of all the costs involved. For instance, part of the total time spent down is not just the repair itself, but how long it takes for a technician with the right tools to get to the machine and do what needs to be done. This means we have to add in travel time, the time it takes to do the repair, parts for the repair, and so on. Once we understand every point, we can then start our search for real-world solutions. Some of the additional expenses we need to be aware of are:
- Machine Cost: Loss of expected usage
- Collateral Damage
- Replacement Costs (Rentals)
- Repair Fees
So as we can see, it’s not such a simple matter when trying to put a dollar figure to the total cost of unexpected downtime. There are many things that are easily overlooked. Over the next few weeks, I’ll be doing my best to clear up some of the mysteries for you. The information will be brought to you in a series of articles and videos:
I hope you’re enjoying the Equipment Downtime series. Continue reading Part 2, Part 3, Part 4, Part 5, Part 6, and consider downloading my exclusive whitepaper on the subject.
