Equipment downtime management largely focuses on a subset of systems, particularly automated machinery and mechanical systems, rather than IT and software solutions. It involves planning for physical breakdowns, mechanical failures, worn parts and injured laborers. While those concerns can still exist today, downtime is also a software-related issue originating with IT solutions.

Common Causes of Equipment and Operational Downtimes

Unplanned downtime can become costly, with industrial companies losing more than $50 billion per year due to mismanaged output and idle time. When production halts, companies hemorrhage money. It is essential to identify and address problems to mitigate interruptions effectively.

1. Software Bugs and Outdated Firmware

Out-of-date or unpatched systems are likely to experience integration failures, especially when working with interconnected devices. Without a scheduled upgrade process, they’ll eventually fall out of line. This can halt production or create serious cybersecurity vulnerabilities that could lead to more damaging outages later.

2. Poor Network Management and Instability

Networks that weren’t designed to handle lots of traffic often experience bottlenecks or performance drops. They may have limited signal strength and reduced coverage. Aging switches or equipment, poor segmentation and unmanaged traffic can also create problems.

Power outages also damage networks, and the U.S. Department of Energy expects their frequency to increase by 100 times in 2030 due to increased loads and the retirement of existing infrastructure. Understanding these faults and establishing a series of checks and balances can go a long way toward maintaining operational stability.

3. Critical Software Failures and Incompatibility

Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES) are integral to manufacturing and industrial operations, but they’re not infallible. Something as simple as a database overload can shut down these systems, creating delays in operational procedures, planning and other administrative work. ERPs and MESs must be updated regularly and tested for bugs and failures. Since they are deeply integrated with modern infrastructure, they require specialized knowledge to be installed and maintained.

4. No Real-Time Monitoring or Alerts

System failures, malfunctions and bugs often occur when you least expect them. A server may fail during the early morning hours, or a switch can malfunction during peak production hours. Unexpected power outages shut down automated systems for hours. In response, real-time monitoring and alerts solutions can provide actionable controls and alert individuals who can take action.

5. IT and OT Convergence Problems

Bridging modern information tech and digital solutions with operational tech, especially when physical processes and solutions are in play, is complex. Often, providers and installers work with in-house engineers to build custom systems or address unique situations. It also leaves a lot of room for mishaps. System failures, network issues, improperly configured firewalls and IT infrastructure — not designed with OT integration in mind — can halt production.

6. Flawed Partner and Vendor Integrations

Bottlenecks in your operations can be caused by partner and vendor integrations that restrict the real-time flow of data. These external organizations may also be experiencing equipment and operational downtime in their workflows, which can ripple through the supply chain.

How to Properly Address Equipment Downtime Management

There are practical ways to address downtime, particularly by tailoring in-house service teams to focus on software maintenance.

Adopt an In-House Support Desk

Hiring and training enough in-house IT professionals to maintain a support desk is highly beneficial. With enough resources, they could service a 24/7 support line that’s always ready to provide technical support, precisely when downtime strikes. Optionally, hiring a third-party provider to manage the help desk may address resource limitations.

Establish Real-Time Observability Across IT and OT Systems

The team needs full visibility into operational systems, from the network and servers to the ERP and MES performance and software maintenance logs. A unified dashboard can manage all of this data with real-time metrics and software tools, reducing guesswork. In a SimuTech Group survey on engineering downtime, 52% of respondents shared that a single hour of downtime costs their facilities $50,000 or more on average. The faster you can respond and fix a problem, the less costly the impact.

Create Redundancy for Mission-Critical Infrastructure

Organizations must plan for network failures and issues. Contingencies such as power backups, cloud resiliency and failover solutions are essential. For instance, a $50 billion investment in power redundancy solutions is economical if it can reduce direct or indirect losses by just 5%. Manufacturing professionals should take proactive efforts to reduce the likelihood of failure and to mitigate its effects.

Schedule Software and Soft Maintenance Inspections

The core systems are constantly undergoing rigorous inspections and checks. However, a rework of existing software systems, such as administering necessary firmware updates, may be overlooked. Penetration testing and visual inspections of electrical components are crucial practices for patching vulnerabilities and reducing threats.

Create Advanced Training Regimens for All Affected Staff

While IT professionals have intimate knowledge of software applications, they may lack the expertise required to work with physical machines or OT solutions. Conversely, warehouse and machine engineers may have a solid understanding of hardware but not of software. Training your staff about how the IT and OT systems integrate can give them a more complete understanding of the manufacturing network.

Structure a Reliable IT/OT Foundation

Creating a clear line of sight into malfunctions and failures enables all stakeholders to understand standard operating procedures and their responsibilities. Establish clear system ownership, define shared standards and build out protocols for individual teams. This is especially vital for incident response teams and in the event of unexpected software or system errors.

Protection Through Real-Time Monitoring and Network Visibility

Costly downtime can affect operations and the rest of the connected supply chain. As modern manufacturing solutions become more intelligent and digitally aware, it is important to strengthen real-time monitoring and alerts, increase network visibility and build response plans for when problems arise.

Lou Farrell is the Senior Editor at Revolutionized, and has several years of experience covering

cutting-edge topics in the fields of Robotics, AI, and Manufacturing. He enjoys writing more than

almost anything else, and has an intense passion for sharing his knowledge with anyone he

can.