Preventative maintenance is a popular maintenance strategy because it brings a lot of benefits while, at the same time, isn’t particularly hard or expensive to implement.
That being said, preventive maintenance does have its downsides.
One of the most cited objections is that implementing it means you will be doing excessive maintenance. In other words, your technicians will spend time inspecting and maintaining assets that might not (yet) require that level of attention.
If we dig a little deeper, we will see that this leads to a bigger issue. When you are doing preventive work on an asset, in a lot of cases, that asset needs to be shut down first.
As nobody wants to shut down an asset during peak production times or for a maintenance work that doesn’t have to be done yet, let’s see how you can develop a maintenance schedule that takes into account those challenges and minimizes planned downtime.
What Is Planned Downtime?
Simply put, planned downtime is a time you reserve for scheduled maintenance and upgrades during which your assets have to be shut down.
Since proactive maintenance is often done on critical assets that are important to production, you just don’t have any other solution than to pause normal production operations until the repairs/inspections/upgrades are done.
One way that organizations look to avoid these problems is to schedule maintenance during night shifts when the machines are not used anyway. However, if your maintenance department isn’t running night shifts or if you have 24/7 production cycle, finding the right time to schedule planned downtime can get really complicated, really fast.
Planned and Unplanned Downtime
The difference between planned and unplanned downtime is pretty self-explanatory: YOU decide when you want to have planned downtime, MACHINES decide when they want to take a break and they don’t bother asking whether that fits your schedule.
All jokes aside, unexpected equipment failures that lead to unplanned downtime can be very costly, which is one of the key reasons why many businesses are switching from reactive to preventive maintenance.
Knowing how much time you spend on planned vs unplanned maintenance is really important so it is one of the many things that Limble keeps track of for you.
Here is an example of how you can use Limble to track how much time you spend on planned maintenance tasks vs how much time you spend reacting to unplanned issues:
Let’s see how to schedule planned downtimes so you can conduct proper maintenance with a minimum impact on your production speed and volume.
How To Manage Planned Downtime
#1) Understand your production
Throughout the year, you will more than likely have an ebb and flow in a day to day production. Know each machine you run, and discern how different seasons affect production cycles, and in turn, machines daily use.
During peak production, plan to find the best time that affects the bottom line the least. This might mean after hours. Or, if you’re running a 24/7 shop, it might mean the slowest hour of the day.
The key is knowing when production slows down and when it speeds up in order to plan ahead.
#2) Reduce excessive maintenance with a CMMS
One of the principal ways of running a successful maintenance plan is being able to organize, manage, and track large amounts of information across various sources.
Having a modern CMMS can greatly help you track and make sense of all of that data.
Here are just some of the things you do with a CMMS:
- record machine performance and asset history
- track the progress of all tasks (read work orders)
- track the usage of all inventory and spare parts
- track technician’s performance
- schedule and oversee your complete preventive maintenance schedule
By having all of this data at your disposal, you can reduce excessive maintenance by:
- spacing out the frequency of maintenance work on assets that can handle it
- cutting the length of the downtime by speeding up diagnosing and team communication
- ensuring all spare parts are available when you need them
- having a well-organized maintenance department in general
#3) Narrow the focus of your maintenance plan
A great way to know where to begin your maintenance scheduling is by listing all of your assets and assigning a rank to them. It might seem obvious, but knowing which machines are of the highest priority in your factory will give you a north.
Once you have listed your important machines, list the more minor assets that might be so secondary they do not need to be included in routine maintenance.
Certain machines, for example, take less strain with use. One might not need oil or lubrication; another might simply be less involved than other machines, with far less moving parts.
Either way, certain machines need less over-all maintenance. And it should be clear which machines fall under this category. After all, it is often not worth to have all of your machines on a preventive maintenance plan.
In addition to everything mentioned, understanding how long each maintenance task should last and when the machine is used the least will be crucial in creating an effective preventive maintenance plan so that you can schedule planned downtime at the most opportune moment.
#4) Have a clearly defined SOP
Having clearly defined standard operating procedures for every operation that has to be repeated often is a great way to streamline your maintenance operations.
As planned downtime is something you will have to schedule fairly regularly, having clear guidelines will help technicians perform their work faster, which means that your assets will need less time to get back to work.
Keep in mind that the speed and quality of the performed maintenance work are equally important. While it is nice to keep planned downtime at a minimum, poorly performed maintenance work will almost certainly lead to an increase in unplanned downtime.
And I think we can all agree that two additional hours of planned downtime are much more acceptable than a whole day of an unplanned shutdown.
#5) Understand your bottlenecks
Frequent delivery delays make it hard to keep a stock of needed spare parts? Some senior maintenance technicians retired or left the firm so you are working with a younger team that lacks experience and training? Working with older assets that need a lot of attention and like to unexpectedly break down?
In the context of minimizing planned downtime for preventative maintenance, spare parts, inexperienced/unskilled technicians, and aging assets are the 3 most common bottlenecks you need to schedule around.
The good news is that these bottlenecks are avoidable with a little bit of workaround and foresight.
If your spare parts aren’t getting to you in a timely manner, consider ordering them earlier or switching to a new provider when possible.
When you know you have inexperienced technicians you can:
- pair them up with more experienced colleagues
- have a clearly defined SOP we just talked about
- provide them with the necessary training
- have a more rigorous hiring process
And lastly, you have to find a way to account for aging assets. In most cases, this will mean that you will need to pay special attention to those assets as they can be very troublesome and be the cause of many unscheduled downtimes. Some ways you can do that is by:
- carefully tracking asset history to extrapolate common breakdown patterns so you can look to address them during planned downtimes
- scheduling additional inspections that can be performed while the asset is in function
- installing sensors to perform condition-based monitoring
#6) Reduce the duration of planned downtimes through effective collaboration
Departments that interact with maintenance personnel should be on the same page and able to coordinate routine tune-ups and repairs. As long as everyone understands where the maintenance team will be for every planned shutdown, machine operators, cleaning staff and other workers can start preparing the environment so the maintenance technicians can focus only on what they need to do and ensure minimal downtime.
When the opposite occurs and there is poor communication between departments, it is not hard to imagine different mistakes and accidents that can occur and prolong the time your assets spend on standby.
Do not allow poor organization and communication to be the cause of why your planned shutdowns caused production delays.
When To Schedule Planned Downtime?
Considering how many factors we already discussed above, it is clear that only you can find the right time when to schedule planned downtime at your facility.
That being said, we have a few tips that could help:
- Schedule planned maintenance work after business hours
- Immediately before major holidays
- Before highly anticipated severe weather
- One every two years simulate a blackout and test all critical equipment at once
For more detailed explanations, you can check out my guest post that discusses when to schedule planned maintenance.
It’s All About Planning Ahead
As you can see, with enough planning and organization, you can greatly minimize downtimes during planned maintenance.
Whether it’s during a peak production season, or the slowest season of the year, being organized and having a clear maintenance schedule will ensure your production runs at the highest level and that your machines are in the peak operating condition.
If you are interested in fully exploring how Limble can help you keep planned downtimes to a minimum, leave a comment below or send us a message.