How to Optimize the Overall Efficiency of Equipment

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In today’s competitive market, it’s important to ensure your machines are running as efficiently as possible to avoid losing out on potential revenue. Optimizing the overall efficiency of equipment isn’t always an easy process, but there are a few ways you can do it with a minimal amount of effort and cost. From understanding what is corrective maintenance to implementing predictive analytics solutions, here are six proven ways that will help you optimize production.

6 Proven Ways to Optimize the Overall Efficiency of Equipment

Owning your own equipment can save you time and money in the long run, but not all equipment lasts forever. Every piece of equipment you use has an ideal lifespan, at which point it needs to be replaced or completely overhauled to be operational again. However, you can extend the life of any piece of equipment if you take time to optimize its efficiency levels when you first acquire it. Use these tips on how to optimize the overall efficiency of equipment, so it will serve you well in your business for years to come.

1. IoT-Driven Predictive Maintenance

Analyzing trends is key when it comes to being able to properly maintain equipment. One way companies are doing that today is through predictive maintenance solutions, which leverage machine data and smart technology to identify at-risk machines before breakdowns occur. This means maintenance teams have more time for proactive maintenance rather than correcting problems after they happen, thus optimizing the overall efficiency of the equipment.

2. Cross-functional Problem-Solving Teams

Effective problem-solving starts with good communication between team members, particularly with cross-functional teams composed of production managers, safety supervisors, and operators who will be able to identify root causes more quickly and make better decisions for the overall system optimization. With data analytics now becoming an important part of most companies’ maintenance strategies, having real-time access to information can help too.

3. Spot Problems with Machine Vision

Using image-processing algorithms to analyze a machine’s condition, a camera captures a picture and instantly analyzes it for any signs of wear and tear. Any problems are communicated immediately to workers via text message or email alert so they can make corrections before downtime occurs. It’s also worth noting that operators often don’t notice some types of equipment damage until it starts affecting performance; cameras can help identify these issues without disrupting production.

4. Data-Driven KPIs

Looking at traditional data such as average uptime, the time between breakdowns and lost production isn’t enough; you need additional metrics that provide deeper insights into overall system optimization. The best way to find out where your equipment is broken is through reliable predictive analytics tools that will help you evaluate current performance and predict potential future issues.

5. Tie Your Maintenance Strategy to Your ERP Solution

In today’s fast-paced environment, it can be easy to lose track of equipment maintenance cycles, especially if they aren’t recorded properly in your ERP solution. For example, although there may be work orders for machine maintenance in place on paper, without any reminders set up in your ERP system, they might get missed or overlooked by team members charged with completing them. Improving connectivity with ERP systems means better overall machine performance.

6. Use Electric Actuators

You’ve probably heard that electric actuators are more reliable than hydraulic ones; that statement is true, but they can also help optimize your overall equipment efficiency in a way that hydraulic ones can’t. With electronic systems, you won’t have to worry about dealing with fluid leaks or issues related to constant vibrations, so maintenance teams will spend less time fixing problems and more time on proactive maintenance. As electric actuators continue to get better every year, there will be no need for an operator to make adjustments during operation, which means your system gets better over time without any additional input from anyone.

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