Ungeplante Stillstände durch Werkzeugversagen

Definition

Tool, die and mould monitoring vendors emphasise that a lack of data on tool utilisation, wear and failure patterns leads to avoidable downtime and scrap.[3] Dies in blister, extrusion and diecasting applications are subject to wear and require maintenance or refurbishment after specified shot counts or running hours.[2][5][6] When die and tooling inventory management is handled manually, there is often no reliable record of cumulative usage or preventive maintenance history per tool; operators run until failure, at which point presses stop, in-process material is scrapped, and toolroom staff are pulled into urgent repair. International case studies in tool/die environments show that implementing machine-data-driven maintenance can reduce unplanned downtime by 20–40%.[3] Applying this logically to an Australian packaging line running 6,000 hours per year, with unplanned die-related downtime of 5–10% (300–600 hours), a 30% reduction would save 90–180 hours of uptime. At an assumed contribution margin of AUD 1,000–1,500 per machine-hour in high-volume packaging, this equates to AUD 90,000–270,000 in recovered margin per line per year, plus reduced overtime and emergency toolmaking. Additional losses occur from scrap – a single failed die run can waste tens of thousands of units of packaging material, which at AUD 2,000–5,000 per batch quickly adds up.

Why This Matters

The Pitch: Packaging plants in Australia 🇦🇺 lose 3–8% of available machine time and AUD 100,000–300,000 annually due to unplanned stoppages from poorly managed dies. Automating usage tracking and preventive maintenance on tools recovers this capacity.

Affected Stakeholders

Operations manager, Maintenance manager, Production supervisor, Toolroom supervisor, Planning manager, CFO

Related Business Risks