Downtime as a major cost factor in industry
A recent study by the Deutsche Messe Technology Academy in cooperation with automation specialist Moxa provides insights into the reality of industrial production in Germany: 94 percent of the companies surveyed report at least one unplanned shutdown per month, with an average downtime of 3.3 hours. The effects are serious: according to the study, even one hour of production downtime can cause costs in the millions—especially in highly automated processes. The economic consequences range from missed delivery dates and increased personnel deployment to damage to the company’s reputation among customers.
The study cites the following causes of unplanned downtime as particularly common:
Main causes of production downtime
- Failure of machine components or IT systems
- Lack of transparency regarding the condition of the equipment
- Difficulties and delays in procuring spare parts
The consequences are well known: inefficiency, unplanned maintenance measures, increased stress for technical departments, and a decline in overall equipment effectiveness (OEE).
Greif-Velox uses digital solutions and innovative technology to improve overall equipment effectiveness (OEE) in the long term and addresses precisely these challenges. The systems combine intelligent sensor technology, digital evaluation, and practical support in the event of service calls to minimize downtime and secure processes in the long term.
Predictive maintenance with VeloGuard
Condition monitoring is a key feature for preventing unplanned downtime. Our VeloGuard solution automatically detects typical wear patterns and reports them. Continuous self-tests are used to consistently monitor the condition of critical components. This eliminates the need for time-consuming fault analyses and allows potential malfunctions to be eliminated early and in a targeted manner. The result: higher production reliability, predictable maintenance, and significantly reduced downtime.
Real-time transparency with VeloInside
While VeloGuard takes a preventive approach, VeloInside offers operational control: a digital real-time dashboard provides operators with all relevant plant metrics at a glance. Among other things, the system measures and visualizes availability, performance, and quality indicators in an integrated OEE dashboard. This makes weak points visible at an early stage and allows optimization measures to be implemented in a targeted and data-based manner—an essential step toward proactive maintenance management.
Fast spare parts supply with VeloXparts
A frequently underestimated factor for long downtimes is the procurement of the right spare part. This is exactly where our digital spare parts system VeloXparts comes in: Machine-specific QR codes directly on the system give users immediate access to the relevant parts overview, avoiding misunderstandings, incorrect orders, and time-consuming queries. This reduces downtime, minimizes errors in parts selection, and relieves the burden on technical departments – without additional training costs.
Innovative sealing sleeve technology: UltraRubberBellow
A concrete example of the technical advancement of plant components is our newly developed UltraRubberBellow sealing sleeve. Seals have often been a weak point, especially when handling abrasive materials such as silica. The new sleeve, which can be used with the updated filling nozzle, increases the service life from an average of 2,000 to 10,000 cycles to up to 125,000 cycles – a significant reduction in maintenance, cleaning costs, and material usage. In addition, the EasyBell replacement system allows the sleeve to be replaced particularly quickly, further minimizing unplanned downtime.
Quick help in an emergency: VeloXpert Remote Support
Despite all preventive measures, unforeseeable malfunctions can occur during operation. In such cases, our multi-level support system ensures fast help: With VeloXpert Remote Service, up to 95 percent of all malfunctions can be rectified within 24 hours – without the need for on-site intervention. For more complex cases, our service technicians from our global network are available within one to five days.
Stable uptime is the result of well-thought-out solutions
From predictive maintenance and digital analysis systems to wear-optimized components and reliable service: GREIF-VELOX creates solutions that bring customers a decisive step closer to uninterrupted production.
