When a machine stops in a production line, it's not just the machine that stops - the whole value chain is affected. Lost production time, increased costs, staff frustration and, at worst, brand damage. With a strategic approach, companies can drastically reduce the impact of breakdowns - or even avoid them altogether.
Keeping an ear to the ground in today's industry is no longer just about vigilant operators, but about systems that can detect, warn and guide - in real time.
The cost of downtime - for real
Let's put it in concrete terms. A production line producing goods worth €100,000 per day, with 16 hours of operation, has a cost of almost €9,400 per hour in the event of a breakdown. So a lengthy troubleshooting process can be very costly. If traditional troubleshooting takes 8 hours, this translates into a loss of more than SEK 75 000 - which can be halved with the right support for faster response.
How to react faster - and smarter - with connected production
Connecting machines, systems and people through digital solutions creates a holistic view of production in real time. This allows for faster, more accurate decision-making at critical moments.
For this to work in practice, the right data must be available, interpretable - and reach the right person quickly. This creates a flow where reaction time is minimized, decisions are accurate and work is more coordinated.
- Detect the fault quickly through sensors, machine monitoring and automated alarms.
- Understand what happened with real-time data and history.
- Act now with clear roles, digital workflows and smart decision support.
When the accident happens: How to handle breakdowns with digital support
It is rarely the stop itself that is the biggest problem - it is the time it takes to understand, troubleshoot and act. With the right digital tools, that time can be cut significantly.
When systems support people in the right way, even stressful situations can be managed in a structured way. It's about having clear preparedness, access to facts and the ability to make quick decisions - without compromising on quality.
- Automated alerts and clear roles
To react quickly, the right information must reach the right people right away. Automatic alarms are effective - but only if they are properly configured and there is a clear organization around who is responsible for what.
- Data-driven troubleshooting
When information is collected, searchable and structured, troubleshooting time is dramatically reduced. With access to real-time data and history in one place, it's faster to understand what's happening and draw the right conclusions.
- Digital instructions
Under pressure, it can be difficult to remember every troubleshooting step. Digital checklists, integrated into the systems, reduce both the risk of mistakes and the need for person-dependent knowledge.
- Real-time documentation
Relying on verbal handovers or slips of paper increases the risk of misunderstanding. With real-time documentation, interventions can be monitored, improved and used for learning going forward.
What needs to be in Location to succeed?
Acting quickly when a disruption occurs - or ideally before - requires not only technology, but also structure. Successful companies have built a solid foundation where data is accessible, coherent and usable across the organization.
This requires investing in the right solutions, but it is just as much about designing them to support people in production.
- Real-time machine data - communication between machines and systems via standards such as OPC UA or MQTT.
- Uniform structure of the data, for example with a Unified Namespace (UNS) - a method to gather and standardize information from different systems.
- Integrated systems - SCADA, MES, ERP and maintenance systems communicating with each other.
- Digital workflows for troubleshooting, reporting and feedback.
- Flexible production planning - to quickly redirect resources in the event of a stoppage.
Common obstacles - and how to avoid them
Even with the best intentions, it is easy to get stuck. Many pitfalls are known - and can be avoided with the right preparation. The key is to think user-centrically, prioritizing the most important machines first and ensuring that everyone knows why the change is needed.
Frequent pitfalls:
- You start with the technology, not the needs.
- Data is collected, but not used.
- Systems do not reflect reality - staff do not use them.
- Integration is forgotten, creating new information silos.
- Unrealistic expectations - the solution is expected to solve everything immediately.
Solutions of the future - even smarter responses
Digital support for breakdowns is evolving rapidly. New technologies such as AI, machine learning and digital twins are creating the conditions to not only react faster - but also anticipate and prevent breakdowns before they even happen.
Those who succeed in combining technology with human skills create a truly robust production system.
- Predictive maintenance - detect wear or anomalies before they become problems.
- Automated root cause analysis - get action suggestions based on historical patterns.
- Digital twins - simulate the entire production flow and test scenarios without risk.
From reactive to proactive
To sum up, avoiding breakdowns is not just about anticipating - but having the ability to act. With the right strategies and technical support, companies can turn emergencies into learning moments, reduce downtime and strengthen their competitiveness.
Want to know more about how to create a coherent and flexible digital production environment?
