January 29, 2025

Maximizing Equipment Uptime: Understanding Downtime and How to Improve Machine Efficiency

In conversations about maintenance, we discuss terms such as machine uptime and downtime. For better asset management, you have to understand these terms. This article will explore the following:

• Definitions of Equipment Uptime and Machine Downtime
• How to Calculate Equipment Uptime and Machine Downtime
• Benefits of Higher Equipment Uptime
• Tips for Improving Machine Uptime Percentages
• How a CMMS Enhances Equipment Uptime

Definitions of Equipment Uptime and Machine Downtime

Equipment uptime means the amount of time an asset remains available and operational. Obviously, downtime means the asset is unavailable and non-operational.

A higher machine uptime percentage correlates with increased reliability. Reliability in the machine and, in part, the maintenance department.

Higher incidents in downtime point to potential inefficiencies. These might come from a defective machine or improper preventive maintenance (PM).

How to Calculate Equipment Uptime and Machine Downtime

To obtain the percentage of downtime, you need the number of seconds the machine was down. Example: Widget A lay non-operational for one hour. 60 minutes X 60 seconds = 3600 seconds.

Next, you'll want the number of seconds "observed," or the time the equipment should have been working. In this instance, we'll use ten hours. 10 hours X 60 minutes X 60 seconds = 36,000

Divide the first by the second and multiply by 100. 3600/36000 X 100 = 10% downtime.

For the uptime percentage: 100 – 10 (the downtime percentage) = 90%

Discover how streamlined maintenance processes can elevate production. Learn more.

Benefits of Higher Equipment Uptime

• Increased production time. You have fewer interruptions with fewer "wrench time repairs."
• Lower maintenance costs. With routine PMS, you have fewer unplanned downtime incidents. Technicians stay focused on important tasks.
• Lower inventory costs. Emergencies sometimes incur extra costs.

Don't forget, too, that a well-run stockroom adds efficiency. Technicians find the needed parts sooner.

You can see these benefits in a facility where an assembly line processes or builds a product. One machine failing or breaking down affects the rest of the line. Production halts. You risk increased costs and missed deadlines.

Tips for Improving Machine Uptime Percentages

• Choose wisely. Of course, when investing in equipment, you want the best value, the most reliable. Sometimes, the adage "you get what you pay for" holds true.
• Develop a quality preventive maintenance strategy. Even the best machines need TLC. Routine inspections, cleaning, lubrication, etc.
• Follow manufacturer and regulatory guidelines for upkeep.
• Develop a failure/cause/action system. If a failure occurs, you want to know the type of failure, why it failed, and the solution.
• If possible, have a backup asset to handle the load if the primary piece of equipment fails.
• Training. Not just for maintenance technicians, but machine operators. They should learn what they can do in the form of PMs.

How a CMMS Enhances Equipment Uptime

This software brings better organization to your existing maintenance activities.

Highlights of how a CMMS increases the uptime percentages:

• With a record of assets, you list your related PMs.
• You have an easily accessible history of maintenance.
• You have better preventive maintenance scheduling.
• You have better oversight over resources (parts and labor).
• You have clarity in work orders with details and attached documentation for corrective maintenance.
• A CMMS offers numerous reports to help improve asset management.
• You track equipment readings.
• You establish the failure/cause/action codes.
• Proper use reduces downtime and costs.

Achieving Optimal Equipment Uptime

It comes down to basics. Uptime = good. Downtime = bad. Of course, you can't consider these absolutes.

Efficient and effective uptime means you have the machine at its peak performance. Operators don't try to make the machine perform beyond capacity or do something different from its original design.

Some downtime benefits operations. Planned shutdowns, for example. This way, technicians complete numerous PMs more efficiently than when machines are operating. You experience fewer interruptions with a routine shutdown.

The above needs editing. Unplanned downtime = bad.

However, many companies enjoy the value a CMMS brings. Review the section above about the benefits.

Macon Technologies develops a superior CMMS for the long term. Call 800-922-4336 for details on how MAPCON helps you accomplish better equipment uptime.