In manufacturing, every minute counts. When production lines stop unexpectedly, it’s not just product that’s lost; downtime disrupts labor schedules, order fulfillment, and customer relationships. Even a short delay can trigger ripple effects that reach far beyond the plant floor.
But here’s the good news: Downtime is preventable. With proactive strategies and the right automation partner, you can minimize disruptions, extend equipment life, and protect your bottom line. In this article, we’ll break down the true cost of downtime – and what operations leaders can do to avoid it.
The Real Cost of Downtime
Let’s start with the numbers. Studies show that the average cost of unplanned downtime in manufacturing can range from $10,000 to $25,000 per hour, depending on the complexity and scale of the operation. That includes not only lost production, but also:
- Idle labor: Your team still needs to be paid while waiting for resolution
- Overtime: Rushing to catch up once the line is back online
- Missed deadlines: Late shipments that could damage customer confidence
- Wasted materials: Spoiled or compromised product from line stoppages
- Repair costs: Emergency fixes that are often more expensive than planned maintenance
Even more impactful are the hidden costs, like the toll on team morale, increased stress on maintenance staff, and the hit to your brand when orders arrive late.
Why Downtime Happens (and How to Prevent It)
Downtime isn’t always due to catastrophic failure. In many cases, it’s the result of preventable issues that build over time.
1. Poor Maintenance Planning
Many operations rely on reactive maintenance — waiting until something breaks to fix it. This approach leads to longer disruptions and higher costs compared to a scheduled maintenance plan.
2. Inadequate Training
If your staff isn’t properly trained on the equipment, even minor issues can escalate quickly. Inconsistent changeovers, incorrect loading, or unrecognized warning signs can all lead to avoidable shutdowns.
3. Underspecified or Mismatched Equipment
Not all automation is created equal. When equipment is selected without considering long-term throughput, integration, variance in machine application or service needs, the risk of downtime increases. “Cheap” machinery might look good on paper, but often leads to more frequent issues and harder-to-source parts.
Proactive Strategies to Maximize Uptime
Top-performing manufacturers don’t just hope for uptime; they plan for it. Here’s how:
Preventive Maintenance Planning
Create a schedule for inspections, cleanings, lubrication, and parts replacement based on manufacturer guidelines. Viking Masek offers preventive maintenance plans that ensure systems are serviced before issues arise, helping you avoid the “fix it later” trap.
Pro Tip: Build maintenance tasks into your production calendar to avoid conflicts and missed intervals.
Real-Time Monitoring & Predictive Tools
Leverage IIoT (Industrial Internet of Things) tools that monitor equipment performance in real time. These systems can flag abnormal conditions, like vibration, temperature, or pressure fluctuations — before they cause a breakdown.
Bonus: Predictive tools help shift your team from firefighting to forecasting.
Operator Training & Changeover Efficiency
A well-trained team is one of the best defenses against downtime. Viking Masek provides on-site training and documentation during installation, equipping operators to manage systems with confidence.
Fast, repeatable changeovers are another win: When operators know how to transition between SKUs efficiently, you reduce downtime while boosting output.
Modular, Accessible System Design
Designing packaging lines with modularity in mind makes troubleshooting faster and easier. Components can be isolated, repaired, or upgraded without taking the entire line offline.
Also, systems that prioritize accessibility (e.g., intuitive HMIs, color-coded parts, and clear documentation) reduce the time it takes to identify and resolve issues.
Responsive Support from Your Automation Partner
Even with the best plans in place, things can still go wrong. That’s why responsive service matters. Viking Masek offers rapid-response technical support, spare parts availability, and remote diagnostics to minimize disruptions and get your line back online quickly.
Why the Right Automation Partner Matters
Downtime prevention doesn’t start on the day your system goes down; it starts during your initial equipment selection. A reliable automation partner will design systems for uptime and support you with service, training, and long-term planning.
Here’s what to look for:
- Design-for-Reliability: Does the system use proven, durable components?
- Service Infrastructure: Are technicians and spare parts readily available?
- Integration Expertise: Can they ensure seamless communication with your upstream and downstream equipment?
- Uptime Philosophy: Do they offer training, monitoring tools, and support plans as part of the package?
Viking Masek works with manufacturers across industries to reduce risk and maximize reliability. From system design through implementation and beyond, we support customer teams to ensure they’re positioned for success.
The Bottom Line: Downtime is Preventable
Yes, downtime is expensive. But with the right systems, processes, and partners in place, it's also manageable. Whether you're modernizing an aging line or looking to improve existing reliability, now’s the time to shift from reactive to proactive.
Want a head start? Get a copy of The Packaging Engineer's Guide to Troubleshooting Automation Failures—a practical resource designed to help you stay ahead of the curve.
Let’s keep your packaging operation simple in motion.
