Downtime is one of the biggest challenges in manufacturing. It can lead to lost productivity, increased costs and missed deadlines. Whether caused by equipment failures, human errors or supply chain disruptions, unplanned stoppages can severely impact Overall Equipment Effectiveness (OEE).
But the good news? OEE software can help identify and address these issues, allowing manufacturers to minimise downtime and keep production running smoothly. In this blog, we’ll explore the top five common causes of downtime and how OEE software can provide real-time insights to prevent them.
Why downtime matters in manufacturing
Manufacturing downtime can have serious consequences, including:
- Reduced production output
- Higher maintenance costs
- Delays in order fulfilment
- Increased waste and inefficiencies
By tracking OEE metrics, businesses can analyse availability, performance and quality to uncover patterns in downtime and take data-driven action to prevent future disruptions.
The top 5 causes of downtime in manufacturing
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Equipment failures and breakdowns
Even machines wear out over time, leading to unplanned breakdowns. Mechanical failures, electrical faults and software malfunctions can halt production unexpectedly.
How OEE software helps:
- Tracks machine health and performance in real-time
- Predicts potential failures with condition monitoring
- Schedules preventive maintenance to avoid unexpected stoppages
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Poor maintenance practices
Relying on reactive maintenance (fixing things only when they break) leads to frequent downtime. Without planned maintenance, minor issues escalate into major breakdowns.
How OEE software helps:
- Automates maintenance schedules based on real-time data
- Provides alerts when performance drops, preventing failures
- Reduces unnecessary maintenance costs by optimising service intervals
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Setup and changeover delays
Time lost during machine setup, product changeovers or tooling adjustments can significantly reduce availability on the production floor.
How OEE software helps:
- Analyses setup times and identifies inefficiencies
- Monitors the progression of faster changeovers
- Provides historical data to optimise workflows
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Operator errors
Mistakes during machine operation, incorrect settings or lack of training can cause unplanned stops, rework or defects.
How OEE software helps:
- Monitors operator performance and identifies training needs
- Provides step-by-step digital instructions for standardised processes
- Reduces human error through automation and alerts
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Material shortages and supply chain issues
A machine is only as productive as its materials. Delays in raw materials, incorrect stock levels or supply chain disruptions can halt production.
How OEE software helps:
- Tracks material usage and sends low-stock alerts
- Integrates with ERP systems to optimise inventory management
Reduces wasted time caused by waiting for material
How to track OEE for downtime reduction
To effectively minimise downtime, businesses need to track and analyse OEE data. Here’s how:
Measure downtime events – Record every machine stoppage, including its duration and cause.
Categorise downtime causes – Use OEE software to classify downtime (e.g. breakdowns, setups, supply chain issues).
Analyse trends – Identify recurring problems and bottlenecks.
Implement improvements – Adjust maintenance schedules, optimise workflows and train operators.
Monitor and adjust – Continuously track OEE data to sustain improvements.
Downtime is an unavoidable challenge in manufacturing, but understanding its causes and using OEE software can drastically reduce unplanned stoppages. By tracking equipment health, automating maintenance, improving changeover times and ensuring proper training, manufacturers can maximise efficiency and reduce production disruptions.