6-Month Plan to Reduce Downtime

Our step-by-step guide is based on 10 years of experience operating across diverse manufacturing environments. You'll learn:

  • Checkmark illustration How to set goals, align your team, and choose your pilot line
  • Checkmark illustration What data to collect, how to interpret it, and where to act first
  • Checkmark illustration How Mars achieved 0% unaccounted downtime

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Key insights

Reducing downtime is a critical strategy to increase capacity and boost profitability for all manufacturers.

This guide shows you how to align your team around shared goals, gather meaningful data, and take quick, targeted actions. You’ll learn how to engage operators, build momentum, and scale improvements across the factory.

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  • The cost of downtime

    Downtime doesn’t just halt production — it disrupts supply chains, delays deliveries, and creates costly bottlenecks. It can reduce overall efficiency and hurt customer satisfaction.  According to recent reports, unplanned downtime accounts for up to 11% of revenue losses in the world’s 500 largest companies. Evocon clients typically see a 15% reduction in downtime within 6 months. Our guide helps you do the same.

  • A step-by-step plan for long-term results

    The plan is built around five stages that work in any production environment. It starts by setting goals, building your team, and selecting a pilot line. After training, you’ll identify where time is lost, implement quick fixes, and expand improvements across other lines. The final stage focuses on creating a culture of continuous improvement for lasting results.

  • How Mars achieved 0% unaccounted downtime

    “Now we have 0% unaccounted time. Every single loss is accounted for, we have a very good understanding of the downtime and therefore we can plan improvement initiatives with solid data to make decisions.”

    Jo-Ann Kitshoff
    Continuous Improvement Technologist
    Mars South Africa

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