One of the biggest issues faced when updating vital plant equipment is minimising downtime while making sure repairs or upgrades are carried out safely and effectively. Unexpected downtime may result in large monetary losses, safety issues and reputational harm – especially when crucial equipment is unavailable for protracted time periods.
PREVENTATIVE MAINTENANCE
“An effective and holistic site service programme increases the dependability of site assets,” states Dave Godfrey, head of aftermarket at Rotork. “The programme must be accessible, provide value for money and be customisable enough to cater to different business needs. A potential offering must ensure that the most appropriate response is provided based on the criticality of the application.”
Employing a tailored site service program, such as Rotork’s tiered ‘Reliability Services’, allows businesses to strike a compromise between maintenance costs and downtime risk. This strategy minimises downtime during upgrades by ensuring that crucial equipment, such as actuators, may be maintained without necessitating a total shutdown of operations.
“It is important that there are a variety of optional extras to fit the customers’ needs,” explains Godfrey. “Having this flexibility can improve a site’s overall performance. Service programmes provide a set cost to operators, allowing for the easy management of budgets. Preventative maintenance, such as regular check-ups, replacing consumable parts and calibration, minimises the risks of sudden equipment breakdowns while prolonging its lifespan.”
Businesses may also tailor maintenance plans according to the criticality of their equipment, guaranteeing that high-priority items are serviced more regularly.
REAL-TIME DATA AND ANALYTICS
Reducing downtime can also be effectively achieved by monitoring and evaluating real-time data. Real-time machine status monitoring is provided by management information systems (MIS), such as those offered by companies like HiFlow, which assist operators in identifying and resolving any problems before they cause prolonged downtime. In addition to reducing downtime, this digital revolution increases productivity and improves operational transparency.
Manufacturers should employ MIS softwares that monitors operational performance so that they can react quickly when equipment breaks down. By using these solutions, facilities managers can make data-driven choices that minimise unexpected downtime and maximise uptime while upgrading their plants.
STAGGERED UPGRADES
It makes sense to space out equipment changes so as to avoid the plant’s complete shutdown. Firms should concentrate on updating important areas one at a time rather than updating everything at once. For example, problems such as material carryback or belt misalignment frequently result in downtime in facilities where conveyor belts are an essential component of operations.
Targeted improvements, such better belt cleaners and alignment solutions, can help remove such bottlenecks and ensure that other plant components continue to function. This will also help prevent recurrent problems.
PERFORMING DMAIC ANALYSES
Employing techniques such as DMAIC (Define, Measure, Analyse, Improve, Control) can assist businesses in methodically tackling issues related to downtime during upgrades. This procedure guarantees that causes of downtime are recognised and handled. “Using the DMAIC methodology, packaging manufacturers can systematically address downtime challenges, fostering efficiency, productivity and operational excellence,” says the HiFlow spokesperson.
In the packing industry, for instance, ineffective changeover procedures, antiquated equipment and inadequate staff training can result in downtime. Facilities managers may decrease the possibility of interruptions during upcoming plant improvements by defining the underlying reasons of downtime, measuring its effect and putting improvement plans into action with the use of DMAIC.
ON-SITE MAINTENANCE AND REMOTE MONITORING
Businesses might benefit from on-site maintenance during upgrades to prevent total shutdowns. Essential equipment may be updated or fixed on-site without completely stopping operations thanks to onsite services.
For instance, maintaining actuators and other precision flow control equipment in top working order is essential in companies that depend on them. Critical maintenance may be completed without requiring plant closures thanks to technologies such as on-site valve automation services, which improve operational dependability and safety while also saving time and money.
UPGRADING TO MODERN, EFFICIENT EQUIPMENT
One of the main reasons for downtime is outdated equipment. Smoother operations and fewer disruptions are ensured by routinely updating to more efficient, current equipment. For example, switching to intelligent actuators, which can record past data and offer precise control, can assist increase overall efficiency in sectors where dependability is crucial.
“Regular, accurate information about site equipment will allow for lower maintenance costs in the long-term and grants a better idea of how the operation is performing holistically,” says Godfrey. “Intelligent asset management is a key component of operations and it allows an organisation’s coordinated activity to realise its equipment’s true value.”
TRAINING AND WORKFORCE DEVELOPMENT
Inexperienced staff members have the potential to introduce or worsen downtime during upgrades, even with the best tools and processes. Thorough staff training guarantees that personnel are prepared to tackle any unforeseen obstacles that may emerge throughout the maintenance procedure.
“Investing in comprehensive training programs equips your workforce with the skills needed to identify and resolve issues promptly,” explains the HiFlow Solutions source. “Well-trained employees contribute to error reduction, adherence to best practices and efficient troubleshooting.”
CONTINUOUS IMPROVEMENT
Simplifying processes via the use of strong MIS or enterprise resource planning (ERP) solutions may facilitate the management and scheduling of upgrades. These solutions give facilities managers better access to specific performance insights and real-time data, which facilitates continuous improvement. Workflows may be monitored, analysed and optimised to minimise scheduled downtime and enable the seamless integration of any required updates without significant interruptions.
“Combining customisable preventative maintenance with a predictive programme, such as an intelligent asset management system, can reduce the chance of failure to near zero, reducing downtime, increasing profitability and improving a site’s overall safety,” explains Godfrey.
While minimising interruptions by implementing an organised strategy that includes tiered maintenance plans, real-time monitoring and targeted equipment upgrades. MIS/ERP systems-driven digital transition, ongoing training for staff and using contemporary equipment.