Unplanned production downtime can cause significant losses. See how Epicor helps manufacturers identify and reduce inefficiencies on the production line.
Unplanned downtime is one of the biggest challenges manufacturers face. Every minute a machine stops without warning means lost output, delayed shipments, and extra costs that could have been avoided. Unfortunately, many companies only uncover the root cause of downtime after it has already had a major impact on operations.
Why downtime often goes undetected until it's too late
At many companies, production machine data and the ERP system run separately. The shop floor team may already have noticed a drop in machine performance, but that information isn't systematically recorded or doesn't reach the decision-makers in time.
As a result, corrective action is often taken only after a machine has completely stopped, rather than as a preventive measure.
How Epicor helps solve this problem
- Real-time machine monitoring through IoT. With Epicor IoT integration, machine performance data connects directly to the ERP system. Companies can monitor temperature, operating speed, and machine cycles in real time, so potential failures are detected before they cause full downtime.
- Predictive maintenance based on historical data. With operational data recorded over the long term, Epicor enables maintenance based on actual data patterns, not just generic routine schedules.
- Visibility into production bottlenecks. Epicor's analytics dashboards provide a complete view of the production flow, so management can identify which stages most often hold things up.
- Integrating production data with supply chain planning. Downtime isn't always caused by machine failure. Raw material delays due to inaccurate planning are also a common cause. With integrated data, procurement planning can be aligned more precisely with production needs.
- Reporting that supports fast decisions. When there are signs of trouble, management can access real-time production status reports without waiting for manual reports from the shop floor.
Long-term impact for the company
Companies that succeed in reducing unplanned downtime generally see broader benefits, including higher production output, more on-time deliveries to customers, and more cost-efficient machine maintenance, since preventive action can be planned in advance.
However, these benefits are only fully realized when the system is configured to match each company's specific production processes. Improper configuration can actually produce data that is less relevant to real operating conditions.
Getting the implementation right
The Apergu team helps manufacturers map their production processes end to end, define the indicators that need to be monitored, and configure Epicor so it genuinely supports downtime reduction based on the realities of your production line.
Discuss your company's production downtime challenges with the Apergu team to get an initial assessment and recommendations on the right next steps.
