The Smartest Way to Reduce Equipment Downtime and Repair Costs

"When a machine breaks down, the repair bill tells only part of the story. A £500 component replacement can trigger thousands in additional costs. Production stops dead. Workers stand around getting paid whilst nothing gets made. Rush delivery of spare parts costs two or three times normal prices. Weekend callouts mean double labour rates. Take this example: A bakery's main oven fails on Friday afternoon."

"Contract penalties kick in when deliveries run late. Perishable materials go to waste during long shutdowns. Customer confidence takes a hit. Staff morale drops when every day brings another crisis. The hidden costs add up fast. Emergency repairs drain budgets. Teams get stressed jumping from one breakdown to the next. Good technicians leave for calmer workplaces. Why Prevention Wins Fixing things before they break saves serious money. Every pound spent on planned maintenance typically saves five pounds in emergency repairs. Yet many businesses resist this approach."

Unplanned machine breakdowns impose large visible and hidden costs, including repair bills, lost production, overtime, rush parts, penalties, and wasted perishable materials. Manufacturing firms now lose over £260,000 per hour when production stops unexpectedly, 50% more than in 2019. A small component replacement can trigger thousands in additional losses through downtime and premium service charges. Emergency repairs drain budgets and harm staff morale, increasing turnover of skilled technicians. Planned maintenance and basic equipment management practices prevent many failures and typically yield a five-to-one return by avoiding emergency costs. Starting with the most troublesome assets and tracking costs enables rapid demonstration of savings.

Read at Business Matters