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Don’t Drop The Ball: Make Planned Downtime Your New Year’s Resolution

Published: 07/01/2022

Don’t Drop The Ball: Make Planned Downtime Your New Year’s Resolution

No matter your industry, downtime is a natural part of business. Imagine your production line is going through the motions only to suddenly grind to a halt. We hate to break it to you but you have fallen victim to the dreaded unplanned downtime, one of life's greatest annoyances and it is most certainly time to go back to the drawing board. Planning downtime when maintenance can be carried out is a game changer, allowing you to stay ahead of the curve.


From faulty component replacement to inspection and testing, scheduling downtime can help you to steer clear of unnecessary stress and hard hitting financial implications. Over Christmas and New Year, chances are you have had a well deserved break and given the same courtesy to your production line. Planning holiday shutdowns is an inevitable part of maintenance management. So, why is planned preventative maintenance so important and how can you kick things back into high gear without incident? 


Once you’ve overindulged on the festive buffet and sung your heart out to Auld Lang Syne, Northern Industrial are here to offer an automated helping hand.

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Planned vs Unplanned Downtime: Breaking Down The Differences

Unplanned downtime is like the monster which lurks under your bed as a child with the Maintenance Manager living in constant fear of breakdowns. The key element of unscheduled downtime is the unpredictability of it rearing its head. It can happen anytime and anywhere within your production system, sometimes with no warning as it tip toes in to cause chaos. It is highly unlikely that this will occur at a convenient time for you and without a plan, your recovery period will be prolonged, costing you an arm and a leg to boot. 

Comparing planned with reactive downtime is like pitting light and dark against one another. Scheduling downtime minimises the negative impact on your productivity, allowing you to carry out preventative maintenance to boost reliability at a time to suit you. This strategy does not allow machinery to run until the point of failure and instead places the control firmly in your hands as you safeguard your assets.

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What are the benefits of planned downtime?

It is a well known fact that in most cases, it is more cost effective to maintain electrical components than repair them. Allowing machinery to tirelessly run until it fails dramatically reduces its lifespan and is likely to result in a costly fix or even a complete replacement. 



Avoid Unplanned Downtime

This is arguably the most beneficial element of a planned maintenance schedule. Imagine a scenario where you have an order scheduled to be delivered to a customer when suddenly the production line stops. The supervisor is then tasked with identifying the root cause, finding a solution and getting things back up and running. How long will this take you may ask? Well, how long is a piece of string? The fault may be minor and in that case, the customer may receive their order, however if more sizable, production could be out of commission for a considerable period of time. No production, no delivery and therefore potential loss of a valued customer. The knock on impact could be catastrophic and cost you far more than just time. 


Increasing Asset Lifespan, Decreasing Repair Costs

Okay, so you have just invested a considerable amount of money in a new machine but choose to leave it to its own devices with no maintenance. It may sound financially viable as it's a brand new piece of kit, however if a small problem arises after a few months and it goes undiagnosed, what was once a minor fault can become a far more costly issue. Therefore, your return on investment goes out the window and you may even be faced with a repair invoice landing on your desk. Planning maintenance (especially during the holidays) can prevent this scenario from becoming a reality, benefiting your business, your production and of course, your wallet. 


Making Production Regular as Clockwork

Predictability and knowing when your production line needs a little TLC is integral to your business. Orders must be fulfilled and having unplanned downtime make a grand entrance is the last thing you need. If you are a trusted supplier, keeping a firm grasp on that title could very well be dependent on your maintenance schedules and ability to plan downtime. Keeping the workforce in the loop with regards to this planned downtime means orders continue to be completed as the maintenance is scheduled during less busy periods.

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How Can Northern Industrial Help You?

Implementing a preventative maintenance schedule and making the switch from reactive to proactive is the cornerstone of downtime avoidance. Maintenance not only elongates the lifespan of equipment and devices, but also improves overall effectiveness and productivity, positively impacting financial performance. 

Plant Engineering Magazine compiled research into how many companies embrace this approach. The study showed that 78% of facilities have a preventative maintenance strategy in place with 59% incorporating a computerised maintenance management system. This approach allows these facilities to schedule regular maintenance, maximising efficiency. Asset management and having readily available (especially obsolete) parts is a huge factor in reducing unplanned downtime risk. Aging programmable logic controllers and discontinued equipment can take multiple weeks to be delivered, so the dreaded downtime is guaranteed to occur. Having surplus stock and keeping track of availability can be the difference between a speedy recovery and a cataclysmic event.



Enter Northern Industrial, here to help your production line avoid the holiday blues and sluggish restart. So the time has come for you to restart after a break but you are faced with a part failure. Even with a planned downtime schedule in place, issues can still arise but have no fear, we have the solution to satisfy your emergency spares cravings. 



SparesVault™ enables proactive manufacturers to manage obsolescence and reduce unplanned downtime. Our service provides a bespoke obsolescence management system, minimising the effort required to procure obsolete spare parts. SparesVault™ provides an extra layer of protection for those who simply cannot afford the disruption and risks associated with unplanned downtime. We enable you to take charge of your assets and secure spare parts coverage for the future, with minimal up-front costs and without the need to house a huge spares inventory at your site.

Substituting obsolete parts for new technologies can be a costly affair and with many businesses choosing to stick with what they know, our team is on hand to support you and your need for obsolete spare parts with guaranteed availability, a cost effective membership and a two year warranty. SparesVault™ allows our team to manage your inventory (including the condition, storage and availability) but we also have you covered with 24/7 call outs and technical support. If that was not enough, we also commit to a fixed price promise in line with our dedication to transparency, allowing you to budget to your hearts’ content for the duration of your plan. We take out the middleman, stocking all your obsolete parts here in our warehouse, nullifying additional third party costs. Cementing the cherry firmly on top, we pride ourselves on giving you options, offering standard, enhanced and premium options, each with their own repertoire of benefits. 



How does it work?

Plan - We will compile a detailed obsolescence report following a comprehensive, expert led review of your system critical assets. With recommendations for parts to be included in your bespoke SparesVault™ inventory.


Implementation - SparesVault inventory is sourced, tested and checked by experienced in-house Northern Industrial engineers. This stock is then held securely at Northern Industrial's bonded stock warehouse facility.


Delivery - In the event of a breakdown, the relevant part will be despatched within the agreed contractual response time. This includes any add-ons selected such as engineer callout or telephone support.


Review - On a regular basis Northern Industrial will carry out a review of the recommended SparesVault inventory levels and propose adjustments where necessary with your agreement.

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Industrial automation is part of our DNA. If you are on the hunt for a complete automation solution, we are ready and waiting to provide the integrated support you deserve in the fight against unplanned downtime.

No matter your automation requirements, Northern Industrial has you covered. From replacement sensors and HMIs to electrical repairs and spare parts, we do it all. 

Are you ready to unlock your SparesVault™?

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