How to Reduce Unplanned Downtime: A Practical Guide for Manufacturing Engineers
· 10 min read
Unplanned downtime costs industrial manufacturers an estimated $50 billion annually according to Deloitte's research on smart factory operations. The average manufacturer experiences 800 hours of equipment downtime per year — roughly 15 hours per week where production stops, orders are delayed, and money evaporates.
But here's what most guides won't tell you: reducing unplanned downtime isn't about buying more technology. It's about systematically understanding why your machines stop and building processes to prevent those stoppages. Technology is an enabler — not a solution by itself.
This guide covers what actually works, based on decades of manufacturing operations experience.