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In the fast-paced world of manufacturing, time is money. Every minute a machine sits idle, production grinds to a halt, and profits take a hit. While some downtime is unavoidable, like scheduled maintenance, unplanned downtime caused by unexpected equipment failures, human error, or material shortages, can be a devastating blow to a manufacturer's bottom line.

Industries across the board are experiencing spiraling costs due to downtime, but there is a way to alleviate the associated challenges with the integration of cobots.

Unplanned Downtime in Manufacturing

Planned downtime is intentional and happens on purpose to implement updates, upgrades, and configuration changes. The purpose of planned downtime is to prevent unplanned downtime through preventative maintenance, keeping machines and operations at optimal functionality. This particular type of downtime is usually planned to take place during quiet periods to minimise disruption. 

Unplanned downtime on the other hand, is unexpected and can happen at any time. It is one of the most damaging things to happen to a company’s productivity and profitability, with the cost of unplanned downtime going far beyond just lost production. It's a complex web of direct and indirect expenses that can cripple manufacturing operations.

Lost Revenue: The most obvious impact of unplanned downtime is loss of revenue. If machines aren’t running, products are being made, and this decrease in productivity means loss of profits. This can be especially critical for companies with tight deadlines or those operating in industries with high demand. At the same time, all other production costs haven’t disappeared, they continue to pile up throughout any period of unplanned downtime. 

Labour Costs: Even when machines are down, workers still need to be paid. This includes maintenance personnel working overtime to fix the problem, as well as operators who are idle and unable to perform their tasks.

Material Waste and Quality Issues: If a machine breaks down mid-production, raw materials can be wasted. This is particularly costly in industries with expensive or specialised materials. Unplanned downtime can also lead to quality problems, especially if disruptions affect a continuous process. This can result in scrapped products, rework, and even damage to a company's reputation.

Missed Deadlines: Unplanned downtime can cause delays in production, leading to missed deadlines and dissatisfied customers. This can damage relationships with key clients and result in lost future business.

Reputational Damage: Frequent or lengthy downtime can damage a company’s reputation, leading to a loss of trust, customer churn,  and make it harder to attract potential new customers and future business opportunities

Overcome the Challenges of Unplanned Downtime with Collaborative Robots 

Designed to work alongside humans in a shared workspace, cobots are safe, easy to program, and can be used for a wide range of tasks, from assembly and material handling to quality control and machine tending. 

Cobots provide a promising and cost-effective solution to help mitigate the challenges and consequences of unplanned downtime to keep operations running smoothly. Collaborative robots offer: 

Improved Flexibility: Cobots can be easily and quickly reprogrammed to perform different tasks, making them ideal for manufacturers with changing production needs. This enhanced flexibility can help reduce downtime associated with retooling, line changeovers or product variations.

Consistent Performance: Employees inevitably have sick days, and at times due to a range of circumstances there aren’t enough workers to cover a 24 hour production cycle. Unlike human operators, cobots don’t get tired or make mistakes due to fatigue. Their ability to perform consistently and continuously allows for maximum uptime and throughput. Should unplanned downtime occur, cobots are primed to work around the clock as soon as production is up and running again to help meet production deadlines. 

Enhanced Safety: Equipped with safety features that allow them to work safely alongside humans, cobots reduce the risk of workplace accidents and injuries that can lead to downtime caused by health and safety incidents. 

24/7 Operation: Delivering continuous performance to manufacturers, cobots help to increase production and allow businesses to implement a third shift without hiring extra manpower. If production has halted and backed up due to unplanned downtime, this extra capacity can help get things back on track quickly. 

Predictive Maintenance: Cobots can be equipped with sensors that monitor their performance and detect potential problems before they lead to breakdowns. This proactive approach minimises costly unplanned downtime, allowing for planned downtime during quiet periods as well as extending the life of machinery, contributing to overall operational efficiency.

By integrating cobots, manufacturers can build a more efficient, reliable, and flexible production environment. While nobody can predict and plan for unplanned downtime, collaborative robots can help ease the challenges and burdens that come along with the unexpected disruption. 

Enhance Production with Cobots Online

In the competitive world of manufacturing, every minute counts. While unplanned downtime is a major challenge for manufacturers, it doesn't have to be a crippling one. By implementing solutions like cobots, companies can take control of their operations to overcome the challenges and ensure production is running smoothly and efficiently as quickly as possible. 

By investing in technologies that mitigate the challenges of downtime, manufacturers can gain a significant competitive advantage and position themselves for long-term success. Cobots Online is here to help SMEs across the UK find the perfect automation solution for their business. Whether looking to integrate one cobot or a whole fleet, contact our team to arrange a consultation or demonstration at our on-site manufacturing facility.