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What is a Downtime Reduction?

Downtime Reduction is a final result of many years of experience gained in servicing automation equipment for many different industries and companies In Canada, US and abroad. Downtime Reduction is a methodology, a know-how technique and practice of shorting troubleshooting time and simplifying vast number of technical documentation attached to any production machinery and its control.

Who is the Downtime Reduction Group?

We are a group of Professional Engineers, electrical and mechanical technologists, process control engineers, systems integrators, PLC and HMI programmers, SCADA specialists, network installers, and problem solvers. As a part of our regular project development we provide technical training and knowledge update to our customers. It is done on premises with flexible time frames.

How Downtime Reduction works?

There are four main components in downtime reduction process. (1) Creating Unified Logic -- combine all schematics (electrical, process, HMI screen, and PLC logic) into one drawing. (2) Create alarm and fault screens to display all input/output conditions of all software and hardware devices to display their statuses online, offline and during fault states. (3) Use tablet for item (2). (4) Crew training.

What saving can we expect?

Base on our case studies you can expect approximately 50% saving upon implementing Downtime Reduction Methodology. As an example, for each $100M annual gross sale a saving on reduction of downtime will be close to $500,000. It is an industry average to have 2% downtime losses every year, split equally between electrical and mechanical problems. In addition, we expect 1 to 2 min fault detection time.

When can we see your presentation?

You can get in touch by phone (437) 889 -3183 or use the form under the contact page. Alternatively, use the quick and easy online booking page, which is a method we prefer. Our presentation usually takes 20 to 35 min depending on how many people will be present. During presentation, you will get a pretty good idea on our methodology and you will see any losses from downtime of the equipment you have selected for analysis.

Are there plans to modify our PLC?

No, we are not planning to change any existing PLC program. All we need to do is to have a copy of that program and HMI design. We will install an external WiFi WEB server, which we will populate with all inputs and outputs with their normal, current, and prior-to-fault indicators. Each I/O will be displayed in industry colors and texts for easy comprehension and comparison to other displays of the dame I/O.

What is a PLC laptop?

When your plant is of a medium size you might have several PLC technicians who are servicing your production machinery when they go down. If they are new to that equipment they need to connect there laptops and conduct troubleshooting with the use of a PLC software to observe it on the laptop's screen. Those laptops sometimes stop working and need to be fixed and/or replaced. We offer a new Maintenance Laptop and External Hard Drive.

How useful is external hard drive?

When your maintenance laptop is not working or it is used by other electrician, you can still do troubleshooting by using an external hard drive with all software you need by plugging it to any other laptop or desktop and booting it up. It is also convenient to have such a drive when you have many PLC of different make. As a rule, we have only one operating system, usually Windows 7 Pro with the main windows 10 as the main OS.

What is your average project length?

Our regular project consists of six very important parts; (1) System Selection For Analysis, (2) Identifying Production Problems, (3) System Design and Programming, (4) Reducing Fault Detection Time, (5) System Test and Acceptance, (6) Downtime Reduction Training Course. These parts have different duration, however they do not reflect neither production, nor maintenance of the machinery. Generally, it will take roughly 3 to 4 week to complete.

When you become familiar with our approach in saving you money you will ask us to apply it to each and every production machinery you have on the production floor.

Our team has diversified experience in almost all types of PLC, HMI and SCADA systems from all around the world. We also provide technical assistance in procurement, installation, configuration, and programming of huge variety of control systems, regardless where they came from.  Please visit our Services for all things we offer.

Downtime Reduction Group employs registered professional engineer,  electrical engineers with masters degree, certified WEB and graphic designers, networking specialists, radio engineers, process control specialists, instrumentation technicians, certified robotic technologies, certified CAD designers, registered electricians, and professors.

As soon as we do not modify any proprietary PLC or HMI/SCADA programs and we are using just passive remote monitoring displays for fault detection, our liability insurance is covering only errors and omissions. Even though, it might only delay project development without reflecting any production.

When we give you a proposal for a scope of work we need to do on your production machinery and the cost of the project, then you will see the ROI. Our experience shows that typical ROI is between 3 to 6 months, on average. It means that when this period is over you will be able to enjoy full benefits of money savings. There are also hidden benefits from our solution. That is no external PLC classes for you maintenance crew will be required and your maintenance crew can be reduce in size. Additional benefit is a remote help desk on the equipment we have being working right after the end of that project.

Ask us a Question

Feel free to ask Downtime Reduction Group administrator related questions over the phone, or send your question via this form below. Your message will be dispatched directly to our staff who will answer it as soon as they can.

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