Maximizing machine efficiency, minimizing downtime: Achieving peak performance in industry
In today’s industries, machine efficiency is a critical factor in determining a company’s success. Maintaining and optimizing machine availability and industrial performance is not only essential for productivity, but also vital for staying competitive. With stringent environmental regulations and increasing resource scarcity, companies must rethink their strategies. At the same time, unplanned downtime can result in significant financial losses and damage a company’s reputation. Analysts estimate that unplanned downtime cost industrial companies in the Fortune Global 500 nearly $1.5 trillion in 2022, representing 11 percent of their annual revenue (source: industrie.de). Here, we’ll explore actionable strategies to help businesses optimize their machine efficiency effectively and future-proof their operations.
Understanding machine availability, productivity, and efficiency
What is machine availability and why is it important?
Machine availability refers to the amount of time a machine is ready for productive use and capable of performing its intended function. It serves as a key indicator of the efficiency and reliability of production equipment and is often expressed as a percentage of the planned operating time during which the machine is actually operational. Machine availability is closely tied to machine uptime, which represents the total time a machine is running and functioning without interruptions.
Machine efficiency describes the ratio between the work produced and the energy consumed, while maintaining consistent quality. A machine with maximum efficiency achieves its full performance potential at the lowest possible operating costs. The formula for calculating machine efficiency or Overall Equipment Effectiveness (OEE):
OEE = Availability x Performance x Quality (source: OEE-Institute)
This calculation of machine efficiency is particularly critical in high-performance industrial applications such as construction and agricultural machinery, compressors, manufacturing, machining, and engines that must withstand extreme stress conditions.
Factors affecting machine performance
Which factors increase or decrease the efficiency of a machine? Here’s an overview:
- Wear and tear: Over time, friction, stress, and environmental conditions cause components to degrade, leading to efficiency losses.
- Environmental conditions: Pollutants in air, water and liquids, dust, high humidity, and extreme temperatures can significantly reduce the lifespan of machine components, especially when operating heavy equipment in harsh environments.
- Lubrication: Proper lubrication is critical to minimizing friction and wear between moving parts.
- Maintenance: Irregular or insufficient maintenance can result in unexpected and costly downtime.
The rising costs of downtime demand modern solutions
Unplanned machine downtime can have immense financial consequences for businesses. According to a study , the cost of one hour of unplanned downtime across various industries has increased by at least 50 percent compared to 2020. For example, in an automotive plant, one hour of downtime cost $1.3 million in 2019/20, but by 2022, those costs had exceeded $2 million – not to mention the harm to reputation.
Key strategies to improve machine efficiency
So, how can we increase machine efficiency and reduce downtime? There are various strategies that, when combined, can deliver optimal results. These approaches can range from simple to sophisticated, traditional to highly innovative:
- Employee training and awareness: Well-trained personnel can detect potential issues early and respond appropriately. Regular training on maintenance procedures and using machine monitoring systems is essential.
- Optimization of spare parts logistics: Efficient spare parts management significantly reduces downtime. Companies should identify critical spare parts and ensure their availability.
- Documentation and analysis of failures: Every failure should be thoroughly documented and analyzed. This information can be used to prevent future downtime and continuously improve maintenance strategies.
- Preventive maintenance: While predictive maintenance is gaining importance, regular maintenance intervals remain crucial. These should be established based on manufacturer recommendations and operational experience.
- Real-time monitoring: By leveraging sensors and IIoT (Industrial Internet of Things) technologies, machine data can be continuously collected and analyzed. This enables early detection of patterns, anomalies, and potential issues.
- Predictive maintenance: This approach utilizes sensor technology and data analysis to monitor the condition of machines in real-time. Predictive maintenance aims to identify risks that require human intervention and predict the timing of potential failures. As a result, maintenance is performed only when data indicates an imminent failure. This optimizes maintenance intervals and reduces unplanned downtime.
- Data analytics and machine learning: Advanced analytical methods and AI algorithms can detect patterns and anomalies in historical and real-time data. This enables precise predictions about the condition and performance of industrial machines and facilitates automated diagnostics.
- Prescriptive maintenance: In contrast to the predictive maintenance approach, prescriptive maintenance goes a step further. It not only makes predictions about potential issues based on real-time monitoring and data analysis but also provides automated diagnostics and specific actionable recommendations to proactively prevent or resolve problems.
Innovative solutions by MANN+HUMMEL for maximum machine availability
To maximize the availability of machines, companies are increasingly seeking innovative and reliable solutions. We are proud to be among the pioneers in this field as one of the world's leading filter manufacturers – offering both traditional filter products and smart filtration solutions.
Smart filtration solutions: Filter monitoring for reduced downtime
An example of an advanced solution to enhance machine efficiency is our Digital Filter Suite. These modern filtration solutions combine our high-performance filter technologies with specially designed sensors, IIoT technology, and digital services from MANN+HUMMEL. Smart filtration by MANN+HUMMEL is already being used in various areas, such as agricultural and construction machinery or industrial equipment. With our Digital Filter Suite, the lifespan of filters can be optimally utilized while reducing service costs.
Depending on individual customer-specific requirements, Smart filtration solutions for OEM (Original Equipment Manufacturer) customers can be implemented in various alternative solution designs:
The Cloud-to-Cloud solution design is the first choice for forward-thinking vehicles and next-generation machinery typically used in regions with good mobile internet coverage. This Cloud-to-Cloud option allows customers to leverage the full potential of data integration and process automation. Digital services are always kept up to date, and insights generated from connected machines can be seamlessly integrated into fleet and service management portals, enabling automated planning of service operations. The collected measurement data from connected machines are processed anonymously, and data exchange is always secure and end-to-end encrypted.
The Edge and Embedded solution designs are tailored to the needs of vehicles designed for operation in remote areas with poor mobile internet connectivity, where they must always function autonomously. The advantage of independence from connectivity comes at the cost of isolated systems within the vehicle fleet. In such cases, digital services must be manually updated, and measurement data and insights cannot be automatically integrated into service and fleet management portals.
Smart filtration by MANN+HUMMEL: The Cloud-to-Cloud solution design
- Sensors specifically developed for monitoring filter conditions in and on the machine continuously track the status and loading of air cleaners, air filters and liquid filters, as well as the condition of fluids, in real-time, that can impact machine performance.
- The collected data is anonymized and uploaded to the respective OEM cloud via the telematics systems of modern vehicles and machinery.
- The digital services of the Digital Filter Suite in the MANN+HUMMEL Cloud analyze this data within the OEM cloud, providing valuable insights into the current load status of the filters in use. They also make precise predictions about the remaining operational readiness of each filter element.
- The insights generated are transferred to the vehicle operator, as well as to overarching service portals and fleet management systems, through the OEM cloud. This enables smarter, predictive planning of maintenance activities.
The numerous benefits of this solution:
- Prevention of unforeseen maintenance needs and unplanned machine downtime
- Smarter and predictive planning of maintenance activities
- Optimal utilization of available filter lifespan
- Reduction in maintenance and operating costs
- Improved protection for people and machines through continuous air filter monitoring
- Optimization of spare parts procurement
Case study: Improving lubricating oil filtration through highly effective innovations
In addition to digital solutions, we provide filtration products that ensure superior protection in vehicles, machines, and equipment. These products prevent wear and improve both machine performance and equipment lifespan. A specific example is the optimization of lubricating oil filtration in mobile power generators using centrifuges from MANN+HUMMEL:
- Problem: High wear on engine components, resulting in significant maintenance and operating costs.
- Solution: Use of the FM200 centrifuge (see our improved state of the art ESC600 centrifuge or similar MANN+HUMMEL centrifuge solutions) to ensure clean engine lubricating oil.
- Result: The centrifuge effectively protects the machine from soot particles.
- Economic benefit: The conversion costs were amortized in less than 12 months. Annual savings amount to €63,000.
This example demonstrates how targeted improvements in filtration technology with MANN+HUMMEL products can lead to significant cost savings and an overall increased machine efficiency.
Innovations and expertise for the industry of today and tomorrow
Increasing machine efficiency and reducing downtime are critical factors for a clean and sustainable industry. By combining data-driven and physics-based models, companies can optimize their predictive maintenance and strengthen their competitiveness. A key element in improving machine operations is the implementation of intelligent control systems to achieve maximum efficiency.
Trends in industrial performance optimization include:
- Increased integration of AI and machine learning: These technologies enhance the precision of predictions and enable autonomous decision-making in maintenance.
- Augmented reality (AR) in maintenance: AR technologies assist maintenance technicians by overlaying relevant information and instructions in real-time.
- Digital Twins: The creation of highly accurate digital replicas of machines is revolutionizing the simulation and optimization of production and maintenance processes.
- Industrial Internet of Things (IIoT): IIoT is a collective term for technologies within a global IT infrastructure that enables physical and virtual objects in industrial environments to connect and collaborate through data.
- Edge and Cloud Computing: Data processing and delivery are performed flexibly and efficiently – either directly at the "edge" of the machine to reduce response times in critical or safety-relevant applications, or via the internet, where highly scalable services such as processing, storage, databases, and analytics are available anytime and anywhere.
Companies that successfully implement these technologies will be able to maximize their machine efficiency, minimize downtime, and significantly improve their machine availability – a decisive competitive advantage in an increasingly demanding industry. At MANN+HUMMEL, we are ready to support you on this journey.
Contact us – together, we will find groundbreaking solutions for optimal machine efficiency!
