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Summer shutdowns in manufacturing: Disruptive or vital?
July 22, 2024
The start of the warmer months marks the beginning of the planned summer shutdowns that many manufacturing facilities have in place. During peak production periods, some businesses choose to split their operations into more manageable tasks. This strategic move helps ensure long-term operational efficiency, promotes employee well-being, and helps with cost management in modern manufacturing.
While planned maintenance shutdowns offer major benefits, they also pose challenges that can hurt operations and affect the bottom line. As some companies reconsider this traditional practice, it's crucial to weigh both the pros and cons of planned shutdowns. This is to determine if these summer shutdowns are vital or disruptive for modern manufacturing.
At EU Automation, we fully understand the importance of these shutdowns. We are committed to remain operational to provide constant support to our customers during this crucial period of manufacturing maintenance.
Why do manufacturers opt for summer shutdowns?
In the automotive sector, summer shutdowns are a common practice that is commonly followed. Company giants such as Ford, General Motors (GM), and Toyota are known for leading the implementation. For instance, Ford and GM typically schedule a two-week planned maintenance shutdown in July.
This period is crucial for performing manufacturing maintenance, retooling, and preparing for new model year production. In a similar way, Toyota aligns its shutdown with Japan’s Obon holiday in August. They use this time for essential system updates and maintenance.
However, the automotive industry is not the only sector to engage in this practice. Chemical manufacturers like BASF and tyre producers like Michelin also observe summer shutdowns. These companies utilise the downtime to conduct necessary maintenance, upgrade equipment and ensure compliance with stringent safety standards.
Benefits of planned shutdowns
1) Maintenance and upgrades:
Regular maintenance is vital for the smooth operation of any manufacturing facility. Shutdowns provide the perfect window for carry out thorough inspections. As well as, performing repairs, and implementing upgrades without disrupting regular production schedules. This proactive approach helps prevent unexpected breakdowns and extends the lifespan of machinery.
2) Model changeovers:
In industries like automotive manufacturing, the introduction of new models requires major retooling and adjustments. The summer shutdowns provide an ideal frame of time to carry out these changes. In turn, this ensures that production lines are prepared to fulfill new demand without any delays.
3) Employee welfare:
Traditionally, vacation time is taken during the months of summer. Coordinating shutdowns within this timeframe allows employees to take their vacations without affecting production. This has the potential to improve morale while also increasing productivity once operations are resumed.
4) Cost management:
The reduction of operational costs during times of lesser demand is yet another strategic advantage associated with this. By aligning shutdowns with seasonal demand changes, manufacturers can better track inventory levels and operational expenses.
5) Energy savings:
High temperatures in summer lead to increased energy consumption for cooling systems. A temporary stop to production can save a substantial amount of energy. This then helps to lower total costs and maintain environmental sustainability.
Companies that are reconsidering summer shutdowns
Some businesses have recently decided to stray from the typical summer shutdown model. They argue that there is a demand for production schedules that are more flexible and continuous. Implementing flexible maintenance schedules throughout the year may allow companies to maintain continuous production and better respond to market demands. This approach also helps in reducing operational disruptions.
Despite the benefits, there are notable drawbacks to summer shutdowns:
1) Operational disruption:
Major interruption can result from a total halt of production. This is particularly the case in the event of an unexpected rise in demand. For instance, in industries with volatile market conditions, stopping production can result in missed opportunities and lost revenue.
2) Supply chain complications:
It can be somewhat complex to coordinate shutdowns with both suppliers and customers. If key suppliers remain operational while the manufacturer is shut down, it can lead to supply chain inefficiencies. This has the potential to cause delays once production is resumed.
3) Increased pressure post-shutdown:
Resuming operations after a shutdown can put pressure on manufacturing lines to meet backlogged orders. As the pace of production speeds up, this could cause quality control issues and higher overtime costs.
4) Risk of over-reliance on shutdowns:
Regular reliance on shutdowns for maintenance may indicate underlying inefficiencies in continuous maintenance practices. Companies might benefit more from adopting condition-based maintenance strategies that minimise the need for complete shutdowns.
EU Automation: Your partner during shutdowns
Summer shutdowns present both benefits and challenges for modern manufacturers. They offer crucial chances for maintenance, cost management, and employee welfare. However, they also come with risks of operational disruption and supply chain complications.
At EU Automation, we recognise the complexities of summer shutdowns and remain fully operational to support our customers during this critical period. Our dedicated account managers are here to help you with all your automation part needs. Whether you're looking for new, used, reconditioned, or obsolete parts, we have you covered. Our goal is to minimise downtime and keep your productivity levels high.
Feel free to reach out to us today and discover how we can provide assistance for your operations. It doesn't matter if your facility is open or closed during the hotter months, we are here to support you.
