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Are you trying to reduce downtime in your manufacturing plant? Pay attention to these simple tips by the experts to reduce downtime through the process optimization. To know more about downtime reduction and tracking visit: www.downtimecollectionsolutions.comn

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Downtime Reduction Through Process Optimization

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downtime reduction through process optimization




W W W . D O W N T I M E C O L L E C T I O N S O L U T I O N S . C O M

downtime reduction has been the long term goal

Downtime Reduction has been the long-

term goal of all the manufacturing units.

However, it remains a distant dream for

many. Six Sigma processes and Lean

Manufacturing have been the most widely

adopted methods. Yet, many manufacturing

units fail to achieve a good OEE score.

Several factors contribute to this problem.

The focus must be laid on bringing

efficiency in the manufacturing process.

Process optimization is the first step in this


process optimization requires the adoption

Process optimization requires the adoption

of various steps. Plant managers must do

rigorous monitoring of the plant and

machinery. They must unify the quality

data access and ensure better tracking

and reporting of the problems. This will

ensure quick remedial action. The key

word in process optimization here is better

monitoring of the processes. A better

understanding of the machine

performance will help in avoidance of

sudden surprises in form of

manufacturing downtime.

some of the factors which will help in process

Some of the factors

which will help in

process optimization


knowledge is power it helps in making informed

Knowledge is power. It helps in making informed decisions

and takes preventive measures. The biggest reason for

most of the unplanned downtimes is a failure to get

accurate data. The manufacturing units work as one entity

but the various processes within the unit work separately. 




it is important that the data of these processes

It is important that the data of these processes is accessible

at one point. This helps in taking preventive steps in case

the point of problems fails to recognize the issues. 

Downtime tracking mechanisms help in

gathering the data at one point. It makes

optimization of the process easy. The

control unit can recognize the need for

preventive mechanism even if the machine

operator fails to recognize it. This central

mechanism can initiate planned

maintenance to reduce manufacturing

downtime. It will make the process smooth

and help in running it optimally. The

important thing is to figure out the problem

before it blows out of proportion.

the biggest problem of the riddle

The biggest problem of the riddle is to

understand the machines. Continuous work,

overload and ignoring the maintenance

breaks lead to problems. They can be

avoided if the process evaluation is carried

out from time to time. This will help in

understanding the machine and avoiding

surprises. A better understanding of the

machines facilitates Manufacturing Process

Optimization. Sudden failures can be

avoided and the process can be made









Optimal performance of the machines is crucial for

optimizing the process. Frequent machine failures and

unplanned breakdowns lead to inefficiency. You can

avoid these problems by monitoring the performance

of the machines. If any machine is facing frequent

breakdowns then you need to get down to the root of

the problem. Low performance of even a single unit in

the assembly will drag down the performance of the

dependent processes. Machine tracking can help you

in understanding this important indicator. It gives you

historical assessment of the performance of the

individual processes.  

accelerate data analysis


The faster you gather and analyze the data the sooner

proactive steps can be taken. It is a crucial part of

process optimization. Downtime tracking gives you

instant access to the machine data. It also gives you

specific analysis of the problems. The area facing the

issue or needing maintenance breaks also get

highlighted. You are able to understand the need for

maintenance better and schedule it accordingly. This

will help you in running the processes much smoothly

where other processes don't get affected by any other

machine's breakdown.

minimize maintenance disruptions



Maintenance is a crucial part of running a plant

smoothly. It can get undermined when a plant is

running at full capacity. This can lead to problems

ahead. Ignoring the maintenance schedules and

overusing the machines can lead to bigger failures. It

must be avoided in all circumstances. Planned

maintenance is a part of process optimization and it

helps in avoiding unplanned downtimes.

unify quality data access



Leaving the analysis of cause and

problems on the individual units can

prove to be a big challenge in the way of

process optimization. Mistakes may get

overlooked and problems may be ignored

under pressure situations. This can spell a

lot of problems where there may be a

complete breakdown of the system.

Access to quality data must be unified.

This helps in maintaining the check and

balance of the system. Even if a problem

gets ignored at one point it will get

noticed at another. This will give a great

boost to process optimization and help in

minimizing downtime.

the process can be run smoothly and without

The process can be run smoothly and

without disruptions. If there is no unified

access to the quality data then you will

have to depend upon the reporting of the

individual machine operators. This may

delay action and lead to undue stops.

Downtime monitoring gives you real-time

access to the quality data. You are

always in the loop and in a better position

to make an informed decision when there

is still time to do so. You can also take

proactive steps through preventive

maintenance to avoid the problems or

reduce the reaction time.  

better tracking and reporting



Better tracking and reporting of the

problems is the key to process optimization.

It always keeps you in the driver's seat. You

have better control over the flow of the

process and you can take steps to make it

better without the fear of many unpleasant

surprises. Downtime Tracking software

programs help you by efficiently tracking

and reporting issues. You have better access

to the key parameters in form of color-coded

signals so that you can easily identify the

urgency. The data is available to you in real

time. This solves the biggest part of the

equation for you. 

you can reduce your downtime by process

You can reduce your downtime by

process optimization. When the

process is moving smoothly there are

very few chances of disruptions.

Problems can be handled easily and

effectively. Downtimes can prove to

be a drag on the resources and put a

lot of strain on other dependent

processes. They must be avoided at

all costs.