Predictive maintenance Software – SmartSignal

Equipment downtime refers to the period when a machine or system is not operational or available for use due to maintenance, malfunction, or other interruptions. It is calculated by dividing the total time an asset isn’t operational by the total expected time of operation. Downtime can be planned, such as for scheduled maintenance, or unplanned, when unexpected equipment issues arise that force a shutdown.

Planned downtime is essential for maintaining equipment health, preventing costly failures, and ensuring long-term operational reliability. When properly scheduled and executed, it minimizes disruption and helps avoid more severe unplanned outages.

Unplanned equipment downtime is especially problematic in heavy equipment industries that rely on expensive and complex technology, such as gas turbines. In these sectors, downtime can have significant financial and operational consequences. For example, organizations such as oil & gas companies or power generation utilities may struggle to meet production targets or service commitments when critical equipment fails unexpectedly.

The most effective way to reduce equipment downtime is by adopting a proactive maintenance strategy. Many organizations today use a mix of reactive, condition-based, and proactive approaches—but minimizing downtime requires anticipating issues before they occur.

To do this, you need:
• Early detection of potential failures
• Optimal outage planning for maintenance
• Spare parts and resource planning
• Near real-time visibility into equipment health

These goals are achievable with the right analytics tailored to the right equipment. For critical assets, leveraging predictive analytics powered by machine learning is key. This technology can forecast equipment issues days, weeks, or even months in advance, allowing you to schedule repairs before damage occurs—avoiding unplanned outages and costly downtime.

Equipment downtime is calculated by dividing the total time an asset isn’t operational by the total expected time of operation.
Downtime % = (Total Scheduled Operating Time/Total Downtime) × 100.

Across asset-intensive industries such as energy, power, chemicals, and mining, preventative maintenance (PM) plays a critical role in reducing downtime and improving operational efficiency. By enabling early detection of issues like wear, corrosion, or misalignment, preventive maintenance helps prevent equipment failures before they escalate into costly and disruptive shutdowns. This proactive approach allows organizations to schedule maintenance during low-demand periods, minimizing operational disruptions and enabling better planning of labor and resources.

Preventative maintenance also significantly reduces the costs associated with emergency repairs, which often involve overtime labor, expedited shipping, and lost production time. With preventive maintenance , companies are more likely to have the time to bring in the right people and parts at the right time, avoiding the chaos and expense of last-minute fixes. Additionally, regular maintenance extends the lifespan of equipment by keeping it in optimal working condition through timely lubrication, calibration, and part replacement.

Beyond operational and financial benefits, preventive maintenance also enhances safety and environmental performance. Routine checks reduce the risk of hazardous incidents such as leaks, fires, and explosions. Because maintenance activities are planned rather than rushed, there is less room for error, which improves both safety and quality. Furthermore, when equipment operates efficiently, it consumes less fuel and energy, leading to lower emissions and a smaller environmental footprint. In this way, preventative maintenance not only protects assets and people but also supports sustainability goals.

Asset failure occurs when critical equipment or infrastructure unexpectedly breaks down, disrupting operations, compromising safety, or causing financial loss.

In the power industry, asset failure can involve equipment such as turbines, transformers, or pumps. These failures can lead to a loss of generation capacity and are often caused by overheating, vibrations, or mechanical wear. Weather events, like lightning strikes, can also contribute to equipment failure.

In oil & gas, assets include pumps, compressors, and offshore platforms. When these assets fail, the consequences can include environmental spills, safety hazards, and production halts. Common causes include corrosion, pressure surges, seal failures, and aging equipment.

In the chemical industry, asset failures may involve reactors, heat exchangers, valves, and storage tanks. These failures can interrupt production processes, cause hazardous leaks, and lead to regulatory violations. Typical causes include material degradation, fouling, and control system errors.

In the metals and mining industry, critical assets include conveyors, crushers, haul trucks, and ventilation systems. Failures in this sector often result in downtime during extraction or processing, safety risks, and loss of throughput. Common causes include mechanical overload, dust contamination, and lubrication failure.

The difference between planned and unplanned equipment downtime is one is scheduled and controlled maintenance, while the other is due to unexpected failures and disruptive. Planned equipment downtime is often scheduled during low demand periods and is typically for maintenance, software updates, upgrades, or inspections. Unplanned downtime, on the other hand, is unexpected equipment failures or breakdowns that halt operations. Common causes are mechanical failures, power outages, or operator errors. The impact is disruptive can lead to safety risks, production delays, and increased costs.

Equipment downtime, whether planned or unplanned, can significantly impact overall operational efficiency in several ways:

1) Reduced Production Output
When equipment is offline, production slows or stops entirely. This is especially critical in power generation and oil & gas operations, where continuous output is essential to meet energy demands and contractual obligations.

Planned downtime can be strategically scheduled during low-demand periods to minimize impact.
Unplanned downtime, however, can lead to missed delivery commitments, regulatory penalties, and potential loss of revenue due to interrupted supply.

2) Increased Operational Costs
Planned downtime allows for cost-effective maintenance, preventing catastrophic failures and extending asset life.
Unplanned downtime often results in emergency repairs, overtime labor, and prolonged outages while sourcing parts—especially problematic in remote or offshore locations.

3) Safety and Environmental Risks
In oil & gas and power sectors, equipment failures can pose serious safety hazards and environmental risks. Unplanned shutdowns may lead to pressure build-ups, leaks, or hazardous emissions. Planned maintenance ensures compliance with safety standards and environmental regulations, reducing the risk of incidents.

4) Disruption to Operational Workflow
Downtime disrupts tightly coordinated workflows across upstream, midstream, and downstream operations:
• In power plants, it can affect grid stability and load balancing.
• In oil & gas, it can delay drilling schedules, refining processes, and distribution logistics.

5) Lower Asset Utilization and Efficiency Metrics
Downtime directly impacts key performance indicators such as:
• OEE (Overall Equipment Effectiveness)
• MTBF (Mean Time Between Failures)
• MTTR (Mean Time to Repair)
• Reduced asset utilization leads to inefficiencies and lower return on investment.

6) Reputation and Stakeholder Confidence
Frequent unplanned downtime can erode trust with customers, regulators, and investors.
Planned maintenance demonstrates proactive asset management and operational discipline.