Blog

Posted on 30 July 2020

Why is planned downtime for maintenance so important?

What is planned downtime for maintenance? 

Planned maintenance downtime is scheduled time when your production is limited or shut down to allow for planned maintenance. 

Often with pressure of delivery deadlines, it is easy for planned maintenance to be pushed down the priority list and only maintain it when the machine starts causing issues or breaks down or when the quality of the products is being impacted. 

 

Why is planned maintenance so important? 

Regular planned maintenance not only safeguards the quality of products produced and stops unplanned downtime, it keeps the machines and equipment healthy, which in turns extends their life span.  

Planned maintenance downtime actually reduces the overall amount of machine downtime, as the machines are kept healthy decreasing the likelihood of unplanned downtime. It is also cheaper to maintain machines than to repair them. 

  • Keeps assets healthy
  • Improves equipment efficiency 
  • Avoids costly unplanned downtime
  • Reduces the total time equipment is offline
  • Extends the lifespan of equipment/machinery due to regular maintenance
  • As more downtime is scheduled, the amount of maintenance needed will decrease
  • Costs less than unplanned downtime

 

How can an Intouch system help schedule your downtime? 

Intouch systems can help you plan your maintenance downtime in three ways: 

  1. Intouch provides a scheduling/planning module that makes it easy to plan downtime at a time which will have the least adverse effect on your production.                                                         
  2. Intouch’s reporting and analytics module lets you analyse the data to decide the optimum regularity that a machine needs maintaining.                                                                                               
  3. Intouch’s monitoring schedule provides constant monitoring of the machines. The data collected is accurate and warns you far more in advance than humanly collated and analysed data would. Allowing you to fix things before they become a costly issue. 

In summary, planning downtime for maintenance, has the following benefits:

  • Can give companies a regular opportunity to collect data about their assets
  • Can detect problems and resolve them without disruption
  • Reduction of overall downtime
  • Leads to greater quality products
  • With no unplanned downtime, you can meet your delivery promises
  • Overall improvement in OEE and profits
planning maintenance downtime

Posted on 3 February 2020

How a manufacturing execution system can transform your plant’s efficiency and profitability

Increased global competition and rising manufacturing costs means that it is now more important than ever to ensure that manufacturers make the most of every resource…read more

Posted on 3 February 2020

How a manufacturing execution system can transform your plant’s efficiency and profitability

In manufacturing, profit is reliant on how efficient the shop floor is. Squeezing everything from your resources without compromising on quality is a challenge increasingly faced by manufacturers. So how can manufacturers stay competitive whilst maintaining or increasing profit?

Continuous improvement is key. Looking at existing processes and finding ways of making these more efficient and cost effective ultimately leads to a more profitable business. Without a mechanism that collects accurate data and standardises current systems, continuous improvement is often reactionary, where problems are only dealt with after they have become costly and problematic.

Making sure that you make optimum use of your resources by installing a Manufacturing Execution System (MES) is a quick, easy and cost effective way. Using Intouch Monitoring as an example, real-time scheduling, monitoring and reporting systems gives manufacturers the visibility to easily make continuous improvement decisions that can contribute to improving Overall Equipment Effectiveness (OEE); improving productivity; reducing lead time and production errors; and raising quality.

Monitoring

Being able to monitor production in real-time and having live and up-to-date information in any part of your factory removes the costs and errors of collecting production data manually. This enables your personnel to use their time more efficiently and the high visibility also motivates production staff to keep machines operational.

Scheduling/Planning

By using a live scheduling module that shows the progress of every job in the plan operators can get a graphical visualisation of machine loading and capacity utilisation.

Jobs can be highlighted for many reasons, such as tool changes, late jobs or resource clashes and takes shift pattern, planned maintenance, overtime and shutdowns into account. Better planning significantly reduces changeover time and the job schedule view gives details of each job enabling operators to prepare for up-coming tool changes.

Reporting

By storing collected data, businesses are able to better track actual materials used and have increased accountability of material use to individual operators, which generally reduces waste. The data enables informed decisions to be made to streamline operations and monitor key processes to better control final product quality and achieve a “zero defect” policy.

https://www.britishplastics.co.uk/blogs/guest-blog/how-production-efficiency-equals-profitable-manufacturing/

Posted on 29 June 2020

How To Choose The Right Manufacturing Execution System (MES) for you

A Manufacturing Execution System (MES) monitors, manages and brings together all the different parts involved in production. Anybody searching for a new Manufacturing Execution System needs to research carefully to make sure that the system offers all the features and benefits required and will provide a significant ROI… read more

 

Posted on 3 February 2020

An MES system can sell you as a supplier

“The Intouch system has without doubt increased our profitability and our blue chip customer informed us that Intouch Monitoring gave us the point of difference compared to other suppliers” OnePlastics Group

Having a monitoring system not only provides you with many direct benefits, mainly the increased visibility enables you to make better operating decisions, but it also helps customers decide to choose you. 

Many customers have found that choosing a supplier which uses a good manufacturing execution system acts as a guarantee that they will get their product produced at the best price, on time and with consistent quality.

Posted on 3 February 2020

An MES system can sell you as a supplier

“The Intouch system has without doubt increased our profitability and our blue chip customer informed us that Intouch Monitoring gave us the point of difference compared to other suppliers” OnePlastics Group

Having a monitoring system not only provides you with many direct benefits, mainly the increased visibility enables you to make better operating decisions, but it also helps customers decide to choose you. 

Many customers have found that choosing a supplier which uses a good manufacturing execution system acts as a guarantee that they will get their product produced at the best price, on time and with consistent quality.

Posted on 29 June 2020

ROI on an MES system – What would a 1%, 5% or 30% improvement in OEE mean to your manufacturing plant?

There are many benefits to installing an MES:

  • Significant improvements in OEE
  • Improved productivity
  • Reduction in down time
  • Reduction in labour, energy and scrap costs
  • Improvement in quality and reliability

But perhaps the most surprising is how even a slight improvement in OEE can mean £100,000s worth of savings a year.

For example, using a fictitious but typical plant with 31 machines. An improvement in machine utilisation of under 2%, a slight reduction in scrap rate and a 1% improvement in cycle rates can mean an annual cost saving of £250,000. This is very easily accomplished with the right information at the right time and the means to easily make any adjustments necessary.

We have a simple ROI calculator that gives you an instant and accurate idea of the significant cost savings even a small improvement in OEE can have. This free calculator shows the potential increase in profit and cost reduction achieved with an Intouch system. The calculator allows you to input limitless variables so can be used to calculate different ‘What if’ scenarios helping you with your business and production decisions. The calculator is available upon request.

 

Read here how our customer Hanson Building Products improved their OEE by 20-30%.

  

Posted on 2 February 2020

Do you know what a 1%, 5% or 30% improvement in OEE could mean to your manufacturing plant?

Posted on 2 January 2020

Guest blog: Production efficiency for profitable manufacturing

Posted on 2 December 2019

Industry 4.0 and profitable manufacturing

Posted on 2 November 2019

Guest blog: Production efficiency for profitable manufacturing