We’ve all been there….Peak arrives and kit breaks down repeatedly, largely unloved for 9 months of the year, some dusted off the night before….it’s a nightmare right?
In manufacturing and production environments, periods of peak demand place immense pressure on People, Plant & Process. Let’s talk Plant…..the mechanical kind.
To meet customer expectations while maintaining profitability, it's crucial to ensure that machinery operates at peak efficiency. Achieving this requires a combination of proactive maintenance, standardised processes, and well-trained personnel.
Some key strategies for maximising equipment efficiency during periods of high production demand.
One of the cornerstones of maintaining equipment efficiency during peak production is the implementation of a Planned Preventive Maintenance program (PPM). PPM ensures that machinery is serviced and checked on a regular basis to identify potential issues before they cause unplanned downtime. This includes scheduled inspections, lubrication, calibration, and part replacements at predefined intervals, based on either time or machine usage.
By having a clear, structured maintenance schedule, production teams can address minor issues during off-peak times, reducing the risk of catastrophic failures when every minute of production counts.
In addition to PPM, condition-based monitoring (CBM) is another proactive technique that helps enhance equipment reliability. CBM uses real-time data from sensors placed on equipment to detect anomalies, such as excessive vibration, temperature changes, or unusual sound levels. This real-time data allows maintenance teams to intervene before a minor issue becomes a major problem.
By integrating CBM into your maintenance strategy, you can further reduce unplanned downtime and ensure that equipment operates within optimal conditions, even during periods of high stress.
Maintaining cleanliness and organisation on the production floor is vital for sustaining equipment efficiency, especially during peak periods. The “Clean as You Go” philosophy promotes a continuous practice of cleaning and organising workspaces, tools, and equipment while production is underway. This minimises the buildup of debris, dust, or contaminants that could interfere with the operation of machinery.
Cleanliness also contributes to better visibility, allowing operators to quickly identify any abnormal wear, leaks, or other issues that could affect performance. In addition, a well-maintained and clean machine is less likely to overheat or suffer from mechanical failure, further supporting smooth operation during high-output periods.
Standardising machine settings is critical to delivering consistent output during peak production. Whether it’s temperature, speed, or pressure, having pre-defined settings ensures that machines operate within the parameters designed to deliver optimal performance. Standardisation also reduces the risk of human error and ensures that all operators run the equipment in the same manner rather than each operator having their own way of running and their own tweaks and work-arounds, there’s nothing worse than ending so far away from standard you forget where it started!
This consistency is particularly important when production rates increase, as variations in machine settings could lead to defects, rework, or slow running.
Even with the best technology, well-trained personnel are essential to maximise equipment efficiency during peak production. Skilled operators who understand both the machinery and the production processes can identify small issues before they escalate into costly repairs or downtime. Training programs should be regularly updated, ensuring that staff are familiar with any new equipment, settings, or procedures.
Additionally, cross-training employees on various machines can add flexibility, having a multi-skilled workforce allows the organisation to adapt quickly to shifting demands, reducing bottlenecks and ensuring optimal equipment utilisation.
Finally, a continuous improvement approach is essential to ensure long-term efficiency. During peak production periods, the strain on equipment can reveal inefficiencies or weaknesses in the production process. Data gathered during peak periods and conducting post-peak reviews, can be instrumental in identifying areas for improvement and optimise maintenance strategies, operator training, or equipment settings for the following campaign.
Maximising equipment efficiency during periods of peak production is a multifaceted effort.
By incorporating these strategies into everyday operations, organisations can sustain high levels of productivity and reduce downtime, ensuring they meet peak production demands effectively and consistently.
For support in the coming weeks prior to Christmas production or to plan in Post Peak Review support get in touch to see how Libra Europe can help make your Peak the best it can be.
