Published: April 14, 2025  Updated: April 11, 2025

Improving Machine Uptime for Operational Success

Companies strive for maximum production and efficiency. To do this, they must have operating assets. To keep them operating, technicians conduct preventive maintenance and repairs when needed. This article looks at how to achieve success with machine uptime. Read on to learn more about:

• What Is Machine Uptime and Why It Matters?
• How to Calculate and Track Machine Uptime.
• Understanding High/Low Uptime: Causes, Consequences & Benefits.
• 7 Proven Steps to Improving Machine Uptime.
• How a CMMS Helps in Improving Machine Uptime and Reliability.

What Is Machine Uptime and Why It Matters

Machine uptime refers to the percentage of time a machine remains operational and available for production compared to its scheduled operational time. It signifies the efficiency and reliability of your equipment.

Look at both parts of this definition. Operational and available. You should include both in your calculations.

Operational—When you run the machine. The time(s) it functions.

Available—Those times you don't use the machine but could.

How to Calculate and Track Machine Uptime

You can find the percentage two ways.

1. Measure uptime directly: This involves tracking the total time the machine operates and dividing it by the total observation period (usually a shift, day, week, etc.). You can achieve this through:
• Manual observation. Machine operators or technicians can log periods when the machine is running and idle.
• Automated systems. Modern machines may have built-in sensors or are connected to monitoring systems that track operational status.
2. Measure downtime and subtract from 100%: You might find this easier to track. You can record instances when the machine doesn't operate because of maintenance, repairs, or other reasons. Then use the following formula:
3. Machine Downtime = (Time spent down / Total observation period) x 100
4. Machine Uptime = 100 - Machine Downtime

Both methods will give you the uptime percentage, though the first gives a more direct measurement. Choosing the best method depends on the specific machine and available resources.

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

Understanding High/Low Uptime: Causes, Consequences & Benefits

Common Causes of Low Machine Uptime

Several factors can contribute to low equipment uptime, including:

• Reactive Maintenance: Waiting for machines to fail before fixing them leads to unplanned downtime, disrupting production schedules, and incurring additional repair costs.
• Lack of Preventive Maintenance: Regular inspections and servicing can prevent major breakdowns. Neglecting preventive maintenance allows minor issues to escalate into significant problems.
• Operator Error: Improper operation or inadequate training can lead to equipment damage and downtime. Examples include:
• Operating machine too fast. The person may decide that faster means more productivity. However, the designers built it for a certain speed. Too fast risks safety hazards, internal damage, and defective products.
• Operating equipment too slow. Think of a Formula One race car driven at a sedate 25 or 30 miles per hour. In time, you'll damage the motor. In this case, the makers intend for fast speeds.
• Trying to make the machine do more than its capacity. Again, the fault lies in the mindset. For instance, shoving more raw materials into the machine won't make it produce faster or more.
• Using the equipment for something other than its design. For instance, baking chocolate chip cookies in an industrial oven.
• Failure to power up/down machine. You must follow procedures. Don't risk the safety of the operator or the "health" of the asset.
• Unforeseen Issues: Power outages, sudden equipment malfunctions, or raw material shortages also can cause unplanned downtime.

Consequences of Low Equipment Uptime

Reduced Production Output: Downtime directly translates to lost production time. This affects output and potentially causes delays in fulfilling customer orders.

Increased Costs: Emergency repairs, replacement parts, and lost production all contribute to higher operational costs.

Customer Dissatisfaction: Missed deadlines and order delays can lead to dissatisfied customers, potentially damaging brand reputation.

Lower Morale: Tension arises between production and maintenance. Each may blame the other for downtime.

Benefits of High Machine Uptime

Conversely, achieving high machine uptime offers significant benefits:

Increased Production Capacity: With machines running optimally, production output rises. You meet customer demands and potentially expand your business.

Reduced Operational Costs: A proactive approach to maintenance minimizes breakdowns and unplanned repairs, leading to lower overall operational costs.

Improved Efficiency: Optimized uptime translates to a smooth and efficient production process, maximizing your return on investment in equipment.

Enhanced Customer Satisfaction: Consistent production allows for timely order fulfillment, leading to happier and more loyal customers.

Image Description: A technician conducts preventive maintenance to increase asset uptime.

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7 Proven Steps to Improving Machine Uptime

1. Implement a Preventive Maintenance Program: Develop a comprehensive plan for regular inspections, lubrication, and part replacements. Form the program based on manufacturer recommendations, historical data, and perhaps equipment readings and metrics. This proactive approach identifies potential issues before they escalate into major breakdowns.
2. Invest in Condition Monitoring: Utilize sensors and data analytics to monitor equipment health in real time. This allows you to identify early signs of wear and tear. You have predictive maintenance and prevent unplanned downtime.
3. Prioritize Operator Training: This ensures they understand the equipment, operate it correctly, and can identify potential issues before they become serious. Think about that low morale discussed above. Proper training includes good communication with the maintenance department technicians.
4. Maintain a Spare Parts Inventory: Having critical spare parts readily available allows for prompt repairs, minimizing downtime caused by waiting for replacements.
5. Schedule Downtime for Maintenance: Plan and schedule downtime for preventive maintenance activities during off-peak hours or periods of low production demand. Many companies have complete shutdowns. For these companies, this works to their advantage. Maintenance doesn't interrupt normal operations. They can complete a comprehensive PM strategy.
6. Root Cause Analysis: When breakdowns occur, don't just fix the immediate problem. Analyze the root cause to prevent similar issues from happening again. Use readings and communicate with pre-established codes for the documentation.
7. Invest in Continuous Improvement: Continuously strive to improve your maintenance practices. Analyze data, identify areas for improvement, and refine your approach to maximize uptime over time.

How a CMMS Helps in Improving Machine Uptime and Reliability

A CMMS provides a centralized platform for managing all aspects of your maintenance program.

Streamlined Work Order Management: Generate, assign, and track work orders for preventive maintenance tasks. Prioritize repairs. Process work requests. Have detailed work orders with safety measures, checklists, and attachments.

Attachments provide a lot of value. They can show location, video instructions, and the specific area to focus upon.

Inventory Management: Maintain an accurate inventory of spare parts. Tracking quantities helps you avoid over- and understocking. You have better oversight on when to make purchases…and the CMMS software helps there, too!

Reports: Analyze historical maintenance data to identify trends, optimize maintenance schedules, and predict potential equipment failures.

Improved Communication and Collaboration: Enhance communication between maintenance teams and operational staff. Everyone stays on the same page regarding equipment health and maintenance needs.

Final Thoughts: Strive for High Machine Uptime and Lower Downtime

What do you need to have success in machine uptime?

• Dedication. Trained employees who commit themselves to keeping asserts running as designed.
• Discipline. Don't neglect PMs just because everything looks good. Attention to detail may prevent bigger problems.
• Communication. Discuss goals, schedules, and accept feedback.

Don't forget about that CMMS. It acts as your central database for information. With proper usage, you'll see reduced expenses and a higher uptime percentage.

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