The ever-increasing utilisation of big data is revolutionising the way Australian manufacturing companies do business. Today’s manufacturers are using advanced analytics to increase yields and reduce costs, with data analysis delivering insights which allow companies to improve process performance and streamline their operations.

But this increased reliance on data and the benefits it presents has not come without a cost. A recent survey found that in 2014 Australian companies lost a massive $65 billion as a direct result of data loss and the subsequent downtime experienced. These losses came from the 64 per cent of Australian enterprises who experienced data loss or downtime in the last 12 months, with 44 per cent experiencing revenue losses and 54 per cent experiencing productivity losses.

The findings show that most companies are unaware of the impact and potential downtime cost of data loss, and are therefore unprepared for the consequences. For Australian manufacturers that are working to near capacity, and where near-zero downtime is the ultimate goal, an unexpected failure can be devastating to operations.

No manufacturer operates without maintenance and recovery plans for machinery as they will be all too aware of the potential consequences. And as the reliance on data as an integral element of day-to-day operations increases, so will maintenance and recovery plans becoming an integral element of a company’s maintenance and repair plans.

Thus, just as preventive maintenance of machinery allows manufacturers greater control over maintenance costing and helps to avoid complete breakdowns and downtime, regular data and network testing should be a growing priority for manufacturers.

With data systems becoming more complex and the maintenance of these systems becoming more specialised, the move towards outsourcing this role is becoming the most viable option for many companies. Establishing a maintenance plan with a respected service supplier that works towards service level agreements and KPIs that suit your company can help ensure maximum efficiency and avoid unexpected and unwanted downtime.

Better understanding of plant performances through increased access and analytics of data should lead a manufacturer’s operations closer to achieving near-zero downtime, not put them at a greater risk of experiencing extended periods of it. 

When a machine stops, it can quickly escalate to calling in external help – sometimes unnecessarily. The Breakdown Checklist is designed to get you back online faster. It will get your team thinking about what caused the breakdown and assess the need for external advice. Download the free downtime checklist here.

SAGE Automation delivers agile, scalable and secure solutions that don’t just solve current problems, they preempt and deter future ones, helping your organisation thrive. With years of experience working in defence, infrastructure, resources, utilities and manufacturing we have the expertise you need to custom-build or perform manufacturing maintenance on your equipment for maximum ROI.