How to Easily Avoid Downtime in Manufacturing With Downtime Management?

Downtime is the bane of any manufacturing owner’s existence. When your production lines are down, your customers can’t access your products or services, and your productivity takes a hit. But downtime doesn’t have to be a death sentence for your manufacturing. With some preparation, you can keep your lines up and running even in a major outage! In this post, we share some tips on how you can easily avoid downtime in manufacturing with downtime management.

How to Easily Avoid Downtime in Manufacturing With Downtime Management?

Schedule Regular Maintenance and Updates

Downtime is a nightmare for every manufacturer. Not only does it cost you money in lost productivity, but it can also damage your reputation if your customers can’t access your product. One of the best ways to avoid downtime is to schedule regular production line maintenance.

You can prevent any potential outages or failures by keeping your systems up-to-date. Schedule these updates during some working pauses, so your productivity isn’t affected.

How Often Should You Schedule Maintenance and Updates?

That depends on your production line. For example, if you have a mission-critical system that needs to be up and running 24/7, you’ll want to schedule more frequent updates. On the other hand, if you have a line that can tolerate some downtime, you can schedule less frequent updates.

However, as a general rule of thumb, it’s a good idea to schedule at least monthly maintenance. This is to ensure that your lines are always running at peak efficiency.

Another vital thing to keep in mind is that not all manufacturing maintenance and updates need to be done at the same time. It’s often better to spread them over time to minimize potential disruptions.

For example, you could schedule an update for the first week of the month, maintenance for the second week, another update for the third week, and so on. This staggered approach will help keep your production lines running smoothly while allowing you to take advantage of the latest security patches and features.

There are several benefits to staggering maintenance and updates:

  • It Minimizes Disruptions: By spreading out maintenance and updates over time, you can minimize the disruptions to your production line. Rather than taking your lines offline for a day or two at a time, you can schedule updates for slow times or overnight so that there is minimal impact on your production operations.
  • It Keeps Your Lines Running Smoothly: You can avoid security breaches and performance issues by keeping your lines updated. By spreading out the updates over time, you can ensure that there is always a minimum level of functionality while still taking advantage of the latest security patches and features.
  • It Improves Efficiency: When everything is scheduled in advance, your IT staff can plan their work better and be more efficient with their time. This also allows them to schedule their work around other projects to be more effective overall.
  • It Reduces Stress: When maintenance and updates are staggered, it takes some pressure off your IT staff. Rather than cram everything into a short window, they can spread the work over a more extended period, which can help reduce stress levels.
  • It Saves Money: In many cases, it costs less to stagger manufacturing maintenance and updates because you can take advantage of discounts or bulk pricing when buying software updates. Additionally, by minimizing the disruptions to your manufacturing, you can avoid the cost of lost productivity.

Create Comprehensive Backup Plans

If something goes wrong, it’s essential to have a backup plan in manufacturing. With a well-thought-out backup plan, you can quickly get your lines up and running again without any losses.

To create a foolproof plan, you must consider digital and physical backups of all your critical data. By taking the time to prepare now, you’ll be grateful later on when disaster strikes.

Digital Backups

In today’s digital age, it’s more important than ever to have secure, remote backups of all your data. You won’t lose everything if you have any crashes. There are two main types of digital backups: local and cloud-based.

Local backups are stored on an external device in a safe location. Cloud-based backups are stored on servers run by companies like Microsoft or Amazon. These servers are located worldwide and are much less likely to be destroyed in a localized disaster.

Both local and cloud-based backups have pros and cons, so weighing your options before choosing one (or both) for your manufacturing is essential. Whichever route you choose, make sure you regularly test your backups to ensure they’re working correctly—you don’t want to find out the hard way that your backup plan failed when you needed it most.

Physical Backups

In addition to digital backups, it’s also essential to have physical copies of important documents in case of a disaster. Store these documents in a waterproof and fireproof safe so they’ll be protected in an emergency.

Test Your Systems Regularly

Imagine this scenario: it’s the middle of a workday, and your production line stops for unknown reasons during the working process. This is just one example of how a downtime in manufacturing can quickly ruin your productivity.

Luckily, there’s a way to avoid these frustrations: by regularly monitoring for potential issues and using machine downtime tracking systems so you can fix issues causing unplanned downtime before it causes a major stoppage of your production line.

Why Test Your Lines?

There are several reasons why it’s essential to test your lines regularly:

  • To Ensure Optimal Performance: By identifying any potential issues early on, you can fix them before they cause your lines to run slower or crash altogether. This way, you can keep your production lines running at peak efficiency.
  • To Avoid Customer Frustration: If your production lines are down, your customers will be unable to do business with you successfully. This can lead to frustration and, ultimately, loss of business. By testing your systems regularly, you can avoid these negative customer experiences.
  • To Save Money: Downtime in manufacturing is not only frustrating, but it’s also expensive. You can save your money in the long run by avoiding downtime.

How to Test Your Systems Effectively?

System testing should be done regularly and during planned manufacturing pauses. Here are a few tips for effective system testing:

  • Identify All Major Components of Your System: This includes carts, conveyor belts, totes & bins, safety equipment etc.
  • Create Detailed Test Cases for Each Component: These test cases should cover everything from functional testing to stress testing.
  • Run Tests Frequently and Consistently: Depending on the size and complexity of your production, you may need to run tests daily, weekly, or monthly.
  • Keep a Record of All Test Results: This will help you track potential issues and identify areas for improvement over time.


Downtime is inevitable for any manufacturing, but it doesn’t have to be a death sentence. By following a few simple steps—scheduling regular maintenance and updates, creating comprehensive backup plans, and testing your production lines regularly—you can keep your manufacturing process up and running even in a major outage!

Francis Nwokike

Francis Nwokike is the Founder and Chief Editor of The Total Entrepreneurs. A Social Entrepreneur and experienced Disaster Manager. He loves researching and discussing business trends and providing startups with valuable insights into running a profitable business. He created TTE to share ideas and tips to help entrepreneurs run and grow their businesses.

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