Unplanned downtime is a difficult challenge to address.
For example, last year I heard a story from an employee at a tissue manufacturer. They had a large coordinated drive system with high-power drives running a tissue machine. At the end of the line, the tissue was wound into a large roll – think an enormous roll of toilet paper.
After 12 years, they started experiencing drive modules faulting, and in some cases failing. When a drive on the machine faulted out and the roll was no longer being driven, the tissue ripped, creating a mess of tissue until the machine was stopped.
Then the tissue had to be cleaned up and the machine rethreaded – slowly restarted by pulling the tissue through all of the rolls on the machine.
Of course, there was also troubleshooting and replacing the faulty drive module. This caused several hours of unplanned downtime and lost production.
Making the situation worse, drives were faulting out every few months, costing this company significant revenue.
The good news is that a majority of unplanned downtime in this situation can be mitigated. How?