Keeping industrial production running is the primary objective of any manufacturing company. Unplanned machine stoppages cause significant losses in economic terms, not to mention negative effects for the company’s image, which are reflected in customer trust.
Improving production processes to be smooth, efficient and reliable represents important added value in any industry.
Nevertheless, failures, human error, natural disasters, faulty software and many other factors can undermine the stability of any process, so it is best to take preventative measures to minimize the chances of production downtime. Here are five useful tips.
1. Review the current workflow
To find out if there are any weak points, you need to understand the details of each area of the production process, which include the following elements:
- People: Do the operators have the necessary skills? Are they supervised by a manager with well-defined, precise, realistic objectives?
- Processes: When was the last time a process was mapped? Have strengths and weaknesses been identified?
- Machinery and technology: Are the machines and devices in good condition? Are the implemented technologies able to meet current needs? How many resources require eventual upgrades? Is the preventive maintenance plan drawn up regularly?
2. Technological updates
After reviewing and diagramming the entire workflow, it is necessary to identify areas where processes and technology require changes or upgrades.
For example, automation is a solution used in some sectors to increase efficiency and reduce the margin of error. New software can help to better manage inventories, control the workflow, and improve company planning. Better machinery increases production quality and speed.
When assessing costs, it is important to consider whether the initial expenses can be absorbed over time by more efficient productivity.
3. Keep to scheduled maintenance
Delaying maintenance, especially if it has already been scheduled, is highly inadvisable. Planned downtime is not a problem as long as it is organized to match the workload.
If, on the other hand, negligent maintenance causes a production stoppage, the problem will grow exponentially with the downtime, not to mention the negative impact on the company’s image in terms of professionalism and reliability.
4. Train and educate employees
The importance of specific training for employees to develop job-related skills is often overlooked.
Initial training is not enough. Rather, there is a need for continuous updates and awareness of an all-round education culture. As well as knowing how to operate machinery, workers must be able to intervene in emergency situations and be familiar with all the safety measures implemented to avoid possible accidents.
5. Apply surface coatings suitable for the purpose of the machinery and devices
Surface coatings are a decisive factor in various sectors of industrial production.
Coated machine components allow for less frequent and shorter maintenance periods. In the chemical or oil & gas sectors, for example, surfaces may come into contact with highly corrosive materials, so a durable, corrosion-resistant coating is the best choice.
In high-speed production cycles and for lightweight, slippery materials, the surface must meet precise traction criteria in order to keep the production process running smoothly.
In plastic and rubber moulding, for example, the use of release sprays can be reduced or eliminated, accelerating processes and removing toxic elements from the working environment. These are just a few examples of the useful application of surface coatings for which Impreglon is a benchmark.
Continuous study and research have enabled us to develop high-quality coatings designed specifically for particular uses.
The patented TempCoat® (non-stick, corrosion-resistant fluoropolymer coating), MagnaCoat® (high chemical resistance), TempCoat 1001® (anti-friction coating for dramatically reduced friction) and PlasmaCoat® (a thermal spray coating that combines hardness and abrasion resistance with non-stick properties) are just a few examples of the wide range of solutions offered by Impreglon. We optimize surface coatings, ensuring safety, performance and reliability over time.