Production or machine downtimes are one of the biggest sources of stress and loss for manufacturers. Whether planned or unexpected, these interruptions have a direct impact on the company’s performance.
Here are the 5 main consequences of a production stoppage for a manufacturer.
1. Immediate loss of productivity
A production stoppage causes an immediate drop in productivity. Every minute a machine is down means products aren’t being made, delivery deadlines are delayed, and overall output decreases. This loss can be compounded by the duration of the interruption, making it harder to get back on track.
2. Increased operating costs
When a machine is stopped, operating costs continue to accumulate. Operator wages, unexpected maintenance, wasted raw materials, and energy expenses pile up. These additional costs weigh heavily on the company’s profit margins, especially if the stoppage was unplanned.
3. Delays on orders and customer dissatisfaction
A production stoppage directly affects the ability to meet order deadlines. Delivery delays lead to customer dissatisfaction, potentially resulting in lost contracts. For companies operating in sectors where deadlines are critical, these delays can permanently damage the manufacturer’s reputation.
4. Risk of equipment failure
An unexpected stoppage, especially one caused by a breakdown, can damage machines. Too frequent or poorly managed restarts increase wear on the equipment, reducing its lifespan and increasing maintenance costs. Worse yet, poor handling of these breakdowns can lead to costly repairs or premature replacements.
5. Decreased competitiveness
Manufacturers that experience regular production stoppages struggle to remain competitive. Faced with more agile competitors who are better equipped to prevent breakdowns and optimize production, companies fall behind. Reduced productivity, higher costs, and customer loss can seriously harm the company’s ability to compete in the market.
Example: Proform identifies its Causes of Downtime and Boosts Productivity with KEYPROD
Proform, a small to medium-sized enterprise specializing in metal bending and forming, optimized its production with KEYPROD. Thanks to this solution, Proform identified and reduced bottlenecks in its processes, resulting in increased production hours and improved revenue. The teams also became more engaged, contributing to overall efficiency.
A production stoppage is more than just an interruption; it can have major economic, technical, and commercial repercussions for a manufacturer. Fortunately, solutions like KEYPROD allow for real-time machine monitoring, anticipating breakdowns, and minimizing downtime to ensure continuous, optimized production.
Try KEYPROD today and discover how to minimize your production downtimes to maximize efficiency.
