Thời gian ngừng máy không kế hoạch đang gây tổn thất lớn cho các nhà sản xuất so với hai năm trước. Chi phí mỗi giờ ngừng máy đã tăng đáng kể, mặc dù số sự cố ít hơn, nhưng tổng chi phí ngừng máy đang tăng mạnh cho các nhà sản xuất.
Đó là những kết quả chính của báo cáo này – cuộc điều tra thứ hai về chi phí thực tế của thời gian ngừng máy trong ngành sản xuất, bao gồm giai đoạn 2021-2022 và cập nhật kết quả từ giai đoạn 2019-2020.
Báo cáo mới cho thấy thời gian ngừng máy không kế hoạch hiện nay gây lỗ cho 500 công ty Fortune Global 500 đến 11% tổng doanh thu hàng năm của họ, gần 1,5 nghìn tỷ đô la. Con số này tăng từ 864 tỷ đô la (8% tổng doanh thu) hai năm trước.
Trong số các công ty Fortune Global 500, chi phí hàng năm cho thời gian ngừng máy hiện đạt 129 triệu đô la mỗi cơ sở, tăng 65% so với khảo sát trước đó vào giai đoạn 2019-2020. Phân tích theo ngành, chi phí mỗi giờ ngừng máy dao động từ trung bình 39.000 đô la cho nhà máy sản xuất hàng tiêu dùng nhanh đến hơn 2 triệu đô la mỗi giờ trong ngành ô tô.
Vì vậy, các công ty cần giảm thiểu thời gian ngừng máy không kế hoạch. Tuy nhiên, họ cũng muốn tránh chi phí lớn của việc bảo trì quá mức – đóng dây chuyền không cần thiết và sở hữu lượng lớn linh kiện đắt tiền và có thể không cần thiết. Bảo trì dự đoán là chiến lược được các công ty áp dụng – một giải pháp đã được chứng minh giảm thời gian ngừng máy một nửa mà không gặp nhược điểm của bảo trì quá mức.
INTRODUCTION
Unplanned downtime is costing manufacturers significantly more than even two years ago. The
cost of every hour of downtime has soared so fast
that, despite there being fewer incidents, the
overall cost of downtime to manufacturers is rising
sharply.
These
are the key findings of this report – our second investigation into the
true cost of downtime in manufacturing, covering
the period 2021-22, and updating of our findings
for 2019–20. This new report suggests that unplanned
downtime now costs Fortune Global 500 companies 11%
of their yearly turnover – almost $1.5tn. This
is up from $864bn (8% of turnover) two years ago. Among Fortune Global 500 companies, the annual cost of downtime is now $129 million per facility, up 65% on our last survey in 2019-20.
Breaking
the costs down by sector, the cost of a lost hour now ranges from an
average of $39,000 for factories producing Fast
Moving Consumer Goods, to more than $2m an hour in
Automotive.
Companies
must therefore minimize unplanned downtime. But they also
want to avoid the significant costs of over-maintenance
– shutting lines unnecessarily and holding extensive
inventories of costly and potentially unnecessary
spares. Predictive Maintenance is the strategy firms are
turning to – a solution proven to cut downtime in half
without the downsides of over-maintenance.
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