How to Reduce Downtime Through Automation Analysis (Guide for Production Managers)

Alex
1 day ago
2 min read

How to Reduce Downtime Through Automation Analysis

In today’s industrial environment, where every minute matters, reducing downtime has become a crucial responsibility for production managers. Automation failures—whether minor interruptions or major breakdowns—directly impact productivity, delivery schedules, and operating costs. Yet most of these interruptions can be avoided through rigorous and continuous automation analysis.

Why Analyze Your Automation Systems?

Automation analysis helps uncover hidden issues within your systems:

drifting parameters,
unstable cycles,
aging components,
overloaded PLCs or drives,
software issues or outdated logic.

This approach transforms a reactive maintenance culture into data-driven, proactive maintenance.

Tip: a yearly full analysis can cut unexpected failures by up to 30%.

Warning Signs of Upcoming Downtime

At Inomatex, we frequently observe the same early indicators:

irregular motor speed variations
inconsistent cycle times
error messages appearing and disappearing
“temperamental” sensors
abnormal temperature rise
repeated station recalibration

These weak signals, often overlooked in daily operations, typically precede a major failure within weeks.

The Most Effective Analysis Methods

a. PLC Program Audit

Structural review, scan times, CPU load, timing logic, outdated or inefficient code.

b. Trend & Data Logging Analysis

Spot drifting values, electrical peaks, pressure drops, or temperature anomalies.

c. Industrial Communication Check

Assessment of networks such as Profibus, Profinet, Ethernet/IP, Modbus TCP, etc.

Unstable communication causes micro-stops that are expensive yet invisible.

d. Safety System Analysis

Unexpected downtime often originates from misaligned safety sensors or aging safety modules.

e. Combined Mechanical + Automation Analysis

This cross-disciplinary approach gives the most reliable diagnosis.

Immediate Benefits

A complete automation analysis allows you to:

minimize unexpected breakdowns,
optimize cycle times,
anticipate component replacement,
eliminate micro-stops,
stabilize sensitive production processes.

Want to uncover hidden performance losses? Request a free pre-analysis of your automation systems.

How to Build a Long-Term Strategy

Implement structured data logging
Document every PLC event
Train your team to read and interpret alarms
Standardize your functional blocks
Conduct a full audit every 12–24 months

By applying these best practices, you transform your automation systems into continuous performance tools, rather than sources of unexpected downtime.

Reducing downtime is not just a maintenance topic — it’s a strategic approach built upon solid automation analysis. For production managers, mastering automation data ensures better anticipation, improved stability, and stronger production performance.