Unplanned downtime costs the average manufacturing facility 5% to 20% of its annual productivity. This results in lost revenue, increased expenses, frustrated customers, and a higher incidence of workplace accidents. There are many causes of unexpected downtime, but proven strategies exist to mitigate them. Working with the right supplier and incorporating the right blade materials for your use case and environment, such as stainless steel or tool steel, are among the most critical steps you can take to reduce downtime in manufacturing.
Planned downtime is expected and accounted for as an operating expense, but unplanned downtime negatively impacts your ability to meet production goals. As a result, it also affects your bottom line. Some of the most common causes of unplanned downtime include the following:
No machine lasts forever, but unexpected equipment failures are often the result of heavy wear and tear on components such as motors, bearings, and blades. When these parts fail, they can take your entire system offline.
Blades are critical to manufacturing processes such as packaging and food processing. If they aren't maintained properly, dull or cracked blades can affect the quality of your products. When this happens, you'll have to shut your line down while you replace them.
Human error is responsible for almost 23% of unexpected downtime. This can happen as a result of operator mistakes in configuring machines or bypassing quality checks. Neglecting scheduled maintenance or failing to heed warning signs can also lead to equipment failure. When workers aren't adequately trained on operating procedures, they can make costly mistakes that damage equipment.
Just-in-time inventory strategies and supply chain disruptions can leave you without spare parts when you need them. Many machine parts, such as blades, have to be replaced as they wear out. If they wear out prematurely and you don't have a backup, you'll have to take your machine offline until a replacement is delivered.
Scheduled maintenance has been a standard part of the manufacturing process for decades. However, advances in data analytics and sensor technology have enabled far more precise models for predictive maintenance.
Predictive maintenance analyzes data from sensors placed in machines to identify early signs of blade degradation, using inputs such as vibration patterns and temperature increases. Based on this information, algorithms predict when blades are likely to fail so you can schedule maintenance before a failure occurs.
The right metal for your blade can reduce your downtime. The best blade material will depend on your use case and the environment.
When you're choosing blade materials, remember that the following properties can increase your blade's lifespan:
Choosing the best blade for your application requires balancing properties based on factors such as the material being cut and the operational environment. For wet or acidic applications, consider using a 420 stainless steel blade for enhanced corrosion resistance. If you're cutting highly abrasive materials, blades made from D2 tool steel will hold up longer.
In addition to material, blade design also significantly impacts cutting quality and durability. Investing in custom engineering for angles, thickness, and bevels can address manufacturing challenges and lead to longer blade life.
Blade geometry affects your machine's performance in several ways. Cutting angles affect your blade's sharpness and edge durability. Sharper angles produce cleaner cuts but wear down faster. A blunter edge uses more force to cut but will last longer in abrasive applications.
Thin blades cut with less force but are more likely to break. Thicker blades can be better for high-power applications. Using the correct bevel reduces stressors such as friction that can cause premature blade failure.
Off-the-shelf blades can work well in general applications, and they're less expensive. However, custom-designed blades will almost always outperform stock blades. When the material and geometry are precisely tailored to your use case, you'll get the best results and longer life from your blades. As with other aspects of blade choice, you need to balance factors. Tolerances overspecification can significantly increase your costs without a proportional increase in performance.
Working with a trusted supplier such as Hyde Industrial Blade Solutions can help you maintain operational continuity. With a fast turnaround time and domestic production, you don't have to deal with long wait times for replacement blades. This is just one way that buying American saves downtime.
Modern manufacturing software can use real-time data from sensors to identify problems with your blades or machinery that may result in equipment failure. If you do experience unplanned downtime, you can use the data and reports to identify and address the root causes for improved performance in the future. This continuous improvement loop can optimize your operations over time.
Establishing standardized procedures and training your operators to use them is one of the most effective ways to improve operational efficiency and reduce downtime. Your operators should be trained on:
A large plastics processor was experiencing a high rate of downtime due to short blade lifespans. After evaluating their processes and blade chemistry, we developed a custom option with stronger abrasion resistance. As a result, they saved over $60,000 annually and increased their blade lifespan by 45%.
Hyde has been manufacturing blades for over 150 years. Our engineering team can collaborate with you to design custom blades tailored to your specific application. Contact us today through our website or give us a call at 508-765-4759 for a free quote.