Avoiding downtime costs caused by sensor failures
Why Standard Sensors Pose a Cost Risk in Hygienic Environments
In hygienic environments, sensors are subjected to extreme conditions. Standard sensors that are not designed for these conditions can cause sporadic errors, false readings, and unstable measurements, which can negatively impact Overall Equipment Effectiveness (OEE).
Quick Check for Downtime Costs
Estimated costs of downtime
Potential Savings Through More Reliable Sensors
High Pressure & Water:
May result in downtime costs if ingress paths at the housing, seals, connectors, or cables are affected.
Chemistry:
Cleaning and disinfecting agents can cause embrittlement or leaks.
Temperature changes:
May cause condensation, which can damage seals and electronics.
Unstable signals:
Even without a total failure, they result in costs due to incorrect switching and safety stops.
The True Cost of Sensor Failures
The cost of the sensor is rarely the largest expense. Rather, it is downtime costs, troubleshooting, quality assurance, scrap, and restart costs that drive up expenses.
| Cost Element | Typical consequence | Exam Question |
|---|---|---|
| Downtime costs | Production Outage | How long will the machine be out of service? |
| Repair Costs | Repair Costs | What are the costs associated with the repair? |
| Commission fees | Production of Defective Materials | How much defective material is produced? |
| Quality Assurance | Additional resources are needed | What additional quality assurance efforts are required? |
| Restart Costs | Costs Associated with the Start of Production | What are the costs associated with restarting operations? |
| Production Downtime Costs | Lost Value Added | How does the outage affect value creation? |
Understanding OEE Pressure: Where Sensor Failures Have an Impact
OEE (Overall Equipment Effectiveness) measures overall efficiency (availability × performance × quality). Understanding the OEE dimensions helps identify sensor failures.
1. Sensor problem:
Incorrect values lead to uncertainties.
2. System response:
Stop or Emergency Mode.
3. OEE component:
Availability, performance, or quality declines.
4. Financial implications:
Direct costs and lost value added.
5. Priority:
High, as it has a direct impact on profitability.
Common causes of sensor-related shutdowns in hygiene and cleaning environments
| Cause | What's happening? | How can we avoid this? |
|---|---|---|
| Moisture ingress | Intermittent errors, often after cleaning | Use of sensors with a high protection rating (e.g., IP69K) |
| Chemical pollution | Corrosion or damage | Use of Chemical-Resistant Materials |
| Incorrect protection rating | Inadequate protection | Preliminary Assessment of the Protection Class |
| Inappropriate connector | The connection may fail | Use the appropriate plug-in system |
| Incorrect Installation Position | Sensor is not working properly | Follow the manufacturer's instructions |
| Temperature Change/Condensate | Condensation impairs function | Choose temperature-stable installation locations |
| EMC/Signal Interference | Interference affects sensors | Distance from EMC sources, shielded cables |
| Incorrect parameter settings | Incorrect switching intervals | Regularly check the settings |
Standard sensor or rugged food-grade sensor technology?
This choice has a direct impact on downtime costs and OEE. Criteria:
Does the error stop the line?
How often is cleaning done?
Are additional diagnostic functions required?
How long does the diagnosis, replacement, and approval process take?
Scrap/Quality Assurance Risk?
Chemistry & Cleaning
Cleaning and hygiene requirements influence the selection and design of components. Specific cleaning profiles, durability considerations, and implementation tips can be found on our separate Hygiene Cluster Page.
Sensors for the Food Industry
Food & Beverage Industry – hygienic, reliable, CIP/SIP-compatible, and ideal for IO-Link.
High-Resistance-Class Sensor Cables (PVC)
For food and wet areas—durable, hygienic, and reliable for everyday use.
Frequently Asked Questions About Downtime Costs & OEE (FAQ)
Downtime costs = downtime × cost per hour. Also take into account quality assurance and restart costs.
Costs vary depending on profit margins, labor, and energy. Take all of these factors into account.
Rely on low-maintenance technology, train your staff, and implement condition monitoring.
Any questions?
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