8 Ways to Reduce Downtime in Manufacturing Environments

Every day, technology advancements offer manufacturers new ways to save time and money and grow their business—until that same technology grinds to a halt. Downtime is the bane of every manufacturer. When operations grind to a halt, it can have devastating effects, costing companies time, money and credibility. 

Reducing downtime in manufacturing involves more than simply maintaining equipment. Strengthening and optimizing IT systems that support your operations can help prevent system failures and keep your business running smoothly. Here are eight ways to do just that:

1. Deploy Tools to Streamline Processes — Advanced technologies can streamline your processes and enhance communication across your supply chain. IT solutions that help manufacturers operate more smoothly include Manufacturing Execution Systems (MES), which monitor and manage the entire manufacturing process, enabling real-time data collection and analysis, and Enterprise Resource Planning (ERP), which centralizes data from various departments, improving coordination and efficiency.
2. Embrace Industry 4.0 for a Competitive Edge — Industry 4.0 or the Fourth Industrial Revolution refers to the dynamic use of technology and cyber-smart systems to create, expand and improve advanced manufacturing solutions. Also called smart industry or digital manufacturing, Industry 4.0’s applications differ depending on the solutions needed to support a manufacturer’s KPIs. Examples include 3D printing, augmented reality, autonomous robots, big data, cloud computing, cybersecurity, Internet of Things (IOT), simulation and system integration. Using advanced digital technologies can increase productivity, lower operating costs, improve product quality, and provide your business with a competitive edge.
3. Embrace AI for Proactive Support – Artificial intelligence is emerging as a competitive edge for manufacturers. When used effectively, AI can transform your maintenance from reactive to predictive. AI solutions can analyze real-time data from sensors and production equipment and accurately forecast potential machine failures, allowing maintenance teams to intervene before costly breakdowns occur and significantly reducing or preventing unplanned downtime. When implemented the right way, AI can boost your overall equipment effectiveness (OEE) and enable you to meet production goals with greater reliability and efficiency.
4. Proactively Monitor and Maintain Systems — Reactive (instead of proactive) maintenance can lead to unexpected outages and lengthier periods of unplanned downtime. Monitoring tools are designed to track your network’s performance, server health, storage capacity, machine conditions and other systems in real time. These solutions alert you when issues arise, allowing your IT team the chance to resolve issues before they impact production lines, ERP systems or supply chains. 
5. Strengthen Cybersecurity to Prevent Disruptions — Preventing a cyberattack is far less costly than recovering from one. A single cyberattack can halt production for days or weeks. Every manufacturer should have a solid plan for cybersecurity which includes key protections such as multifactor authentication (MFA), endpoint detection and response (EDR), network segmentation between IT and OT systems, regular patch management, and employee training.
6. Maintain Reliable Backup and Disaster Recovery Systems — Hardware failures, human error, and cyber incidents happen. The difference is how quickly you recover. Every company should have an established disaster recovery plan that includes automated, tested backups, offsite or cloud redundancy, clear recovery time objectives (RTOs), and regular testing that ensures your systems can be restored quickly when needed.
7. Optimize Network Infrastructure — Manufacturing environments rely on ERP systems, inventory software, connected devices, and increasingly IoT equipment. Maybe you have an ERP, but it isn’t optimized to give you the insights you need, or maybe you’re using spreadsheets to track data. Optimizing your data and systems can power up your productivity and significantly reduce bottlenecks and outages.
8. Standardize and Update Hardware and Software — Outdated systems are unpredictable and can create instability. End-of-life servers, unsupported operating systems, and aging workstations increase crash risks and security vulnerabilities. Keeping your IT and equipment regularly updated and replaced on a regular schedule ensures critical systems remain stable, supported and secure.

Manufacturers spend millions of dollars on manufacturing equipment, but often skimp when it comes to investing in the right technology to keep it running effectively and efficiently. Facility technology systems that aren’t designed for their optimal performance or are poorly secured can leave your business vulnerable, but there are clear steps manufacturers can take to reduce downtime risks. 

At ATB Technologies, we can help you optimize the performance of your tools and get rock-solid IT support when you need it most. Schedule a free consultation today at atb-tech.com/contact-us to learn how we can help keep your business running smoothly.

About ATB Technologies 

ATB Technologies is an award-winning managed service provider (MSP) that helps businesses solve technology problems and navigate which solutions best support their business strategy and goals. Our IT experts help companies maximize their business IT while offering an exceptional level of customer service. We’re ready to help and provide IT support that never lets you down. ATB has been twice recognized by Inc. 5000 as one of the fastest-growing private companies in the U.S. Find out more at atb-tech.com.