Among key performance metrics screaming for attention from today’s manufacturing leaders, the loudest may be the ticking of the clock during periods of unplanned downtime.
Recovery within a critical 24-hour window is the high-stakes benchmark for OEMs, Tier 1 suppliers and other manufacturing leaders, according to Ron Inscho, Sales Manager at Automation Solutions Inc.
“Two hours is a long time on a production floor,” Inscho said. “When you can’t restore operation within those critical first hours, serious losses occur. A manufacturer with production down for 24 hours is a manufacturer whose business may be in jeopardy.”
New research from automations powerhouse Rockwell Automation confirms that leading OEMs rank downtime recovery in less than 24 hours as a critical KPI.
Rockwell polled 500 OEM leaders across 17 countries and summarized the findings in February. The bottom line: Leading OEMs focus on faster recovery via operational consistency and data-based decision-making for stronger performance.
“Rapid recovery is the gold standard – and to get there, manufacturers are focusing on improving their diagnostics and their equipment reliability,” Inscho said. “A manufacturer’s success depends in large measure on how well it collects and monitors its data, and how well it uses that information for predictive maintenance.”
Automations Solutions (ASI) helps manufacturers hit an ambitious recovery KPI in three important ways, Inscho said. The ASI strategy includes smarter installation, remote diagnostics and rapid deployment.
Here’s a closer look at each:
1. Intelligent Design: Monitoring and Detection
The most effective way to recover within the first few hours of unplanned downtime is to ensure the system is designed to “speak up” before a total failure occurs. By integrating systems that prioritize early detection, the window for repair and prevention opens before the production floor goes dark.
“The goal is proactive awareness,” Inscho said. “Whether we are implementing new systems with built-in monitoring or leveraging existing equipment through upgrades, our intent is to build it better.”
Two examples of new systems with impressive capabilities are:
- FANUC-ZDT (Zero Downtime): As a Fanuc integrator, ASI offers ZDT on every R30iB Plus robot and forward. This system monitors mechanical and electrical health, issuing reports based on decades of accumulated data trends.
- ABB Predictive Maintenance: Using AI-driven tools, these systems predict component failure, allowing for proactive maintenance during scheduled stops rather than emergency shutdowns.
When manufacturers are not ready for a full system replacement, ASI leverages existing equipment with strategic upgrades. For example, correcting limited display functions through an HMI upgrade can provide the clear diagnostics needed to turn a potential 2-hour shutdown into a 10-minute fix. Similarly, Small Scale Retrofits serve as a smart bridge to reliability, adding modern predictive capabilities to legacy lines.
2. Seconds, Not Hours: Remote Diagnostic Success
Remote access allows for immediate intervention, often resolving issues in less time than it might take for a service technician to get on the road.
- The 60-Minute Solution: When a palletizing robot at an Alabama cannery went down at 9 p.m., shift operators were unable to identify the cause throughout the night. ASI received an SOS call at 8 a.m. the next morning. Through remote diagnostics, the team determined an input sensor was sending intermittent signals. The fix took just 30 minutes, and the cannery was fully operational by 9 a.m., 12 hours after shutdown.
3. Rapid Deployment: On-Site Restoration
When “boots on the ground” are needed, ASI has a record of getting production lines moving again well within the critical 24-hour mark – even with the logistics of travel. Two impressive examples:
- Under 5 Hours: A composite manufacturer was struggling with a legacy PLC 5 system. A rotating element stopped out of position, cutting throughput to 20 percent. Within five hours – including travel time – ASI discovered a sequencing issue in the PLC, made the necessary tweaks, and restored 100 percent efficiency.
- 90 Minutes: When a local manufacturer’s robot stopped picking parts because a proximity switch failed to detect a pallet, an ASI technician arrived, made the adjustments needed, and had the line at full speed in an hour and a half, including travel time.
Proactivity Over Reactivity
While a fast recovery is vital, long-term reliability is the ultimate goal. Harmful robot programming strategies and incorrect payloads can quietly degrade the health of a robot over time.
ASI recommends starting with a comprehensive engineering study, and uses a thorough evaluation process to determine the correct equipment needs and functionality to provide the highest degree of predictive capability. Whether it’s designing a new system or finding ways to better leverage current assets, the focus remains on keeping the clock on your side.
Ready to beat the clock?
ASI helps manufacturers reach the next-level diagnostics and fast recovery times required in today’s market.
Talk to an ASI integrator today to discuss how Automation Solutions can help turn your manufacturing downtime into a data-driven opportunity for improvement.
