How to handle unplanned demands?

Production is in full swing, the team is working at its limit, deadlines are looming - and suddenly the plant comes to a halt. And then? Unforeseen situations like these put everyone involved under pressure. Unplanned demand in production is more than an operational problem: it is one of the biggest challenges for companies worldwide.

And these situations happen more often than one might think: "Unplanned demand due to machine downtime in production and manufacturing is not the exception, but the rule," says Michael Schlagenhaufer, responsible for the Manufacturing & Maintenance division at Conrad Electronic.

Machine failures in 67 percent of all industrial companies

Current studies such as the "Value of Reliability Report" by ABB support the assessment of the Conrad expert: Despite preventive and predictive measures, 67 percent of all industrial companies experience at least one unplanned machine failure per month. If this lasts for three days, it means an average of 70,000 euros less gross profit for the affected company. Calculating what a machine downtime costs the German economy results in a hefty loss of 147,000 euros per hour.

Professional handling of unplanned needs

The logical question is: How can unplanned needs be prevented and quickly responded to when they occur? “Predictive maintenance undoubtedly helps to avoid machine downtime. However, there are still too many other factors outside the maintenance's sphere of influence that lead to costly production downtimes and the associated unforeseen needs,” explains Michael Schlagenhaufer.

Minimize time and cost stress

Those responsible often act under stress and enormous time pressure in these critical moments. This is precisely when holistic procurement partners are needed to deliver fast and reliable solutions. “Whether large orders for optimal inventory management or individual spare parts in an emergency: For more than 25 years, we have been procuring components, measurement technology, and accessories for machines and systems. Therefore, we are familiar with possible causes, requirements, and solutions for the professional handling of machine downtimes and are happy to share this knowledge on the topic of unplanned needs,” the Conrad expert continues.

"Unplanned needs" - causes, risks, checklists, whitepaper

Anyone who wants to stabilize processes permanently must recognize the causes and take strategic precautions. The new Conrad info pages on the main topic “Unplanned needs in production” provide exactly this support and offer valuable impulses: Interested parties can learn how to not only address unplanned needs with targeted inventory management, strategic purchasing, and smart planning but also systematically avoid them. Also available is a checklist to review operational processes for unplanned needs and a whitepaper that shows how predictive maintenance can enable smoother production.