Episode 36: Defeating Downtime

Jason Reed

Alright, welcome back to The Big Dog Podcast—where we get real about compressed air. I’m Jason Reed, here with Lisa Saunders. Today, we’re talking about something that keeps plant managers up at night: downtime. And not just any downtime—compressed air system downtime. This stuff is expensive, folks.

Lisa Saunders

Yeah, Jason, it’s wild. I mean, the numbers are just staggering. According to Siemens, unplanned downtime costs the world’s largest manufacturers $1.4 trillion a year. That’s, what, up to 11% of their revenue? And if you’re in automotive, it’s even scarier—a single hour of downtime can cost $2.3 million. That’s over $600 a second. I can’t even wrap my head around that.

Jason Reed

It’s brutal. And here’s the thing—compressed air is the fourth utility. We’ve said it before, but it’s worth repeating. If your compressors go down, your whole factory can grind to a halt. Doesn’t matter if you’ve got the best machines in the world—no air, no production. And it’s not just about the air stopping, right? Even minor impurities—oil, water, particulates—can mess up downstream equipment. Suddenly, you’re not just fixing a compressor, you’re dealing with a whole chain reaction of problems.

Lisa Saunders

Exactly. I actually saw this firsthand not too long ago. I was visiting a plant—won’t name names, but they had this tiny air leak that nobody noticed. It started as just a little hiss, but by the time someone caught it, the whole production line was down. And it wasn’t just the compressor—they had to stop everything to check for contamination in the tools and equipment. It’s like, one small issue with your air system can ripple out and cost you way more than just a repair bill.

Jason Reed

Yeah, and that’s why we keep hammering on this. Downtime isn’t just a nuisance—it’s a profit killer. And honestly, a lot of it is preventable if you know what to look for and stay on top of the basics.

Jason Reed

So, let’s dig into what actually causes all this downtime. There’s a laundry list—bad installation, sizing mistakes, overheating, rapid cycling, pressure band issues. We’ve covered a lot of these in past episodes, but the one that keeps coming up, over and over, is poor maintenance. Especially with rotary screw compressors. People just assume these things will run forever if you leave them alone. Spoiler alert: they won’t.

Lisa Saunders

Yeah, and it’s not just about the equipment, right? A lot of companies are downsizing their maintenance teams, or not replacing folks when they retire. So you end up with fewer people trying to keep more machines running, and stuff slips through the cracks. It’s like, you’re gambling with your uptime every day.

Jason Reed

Totally. I’ve seen it happen. There was this local plant—again, not naming names—but they decided to push off an oil filter change. “We’ll get to it next week,” they said. Well, next week turned into a week of unplanned repairs because the filter clogged up, oil flow dropped, and the compressor went down hard. All because of a $20 filter and a half-hour job. That’s the kind of thing that drives me nuts. Routine maintenance is cheap compared to the cost of downtime.

Lisa Saunders

And it’s not just oil changes. It’s the little things—checking drains, responding to alarms, listening for weird noises. If you ignore those, you’re just asking for trouble. I mean, we talked about this in our episode on short cycling, too. Small issues add up fast if you’re not paying attention.

Jason Reed

Exactly. And look, I get it—everyone’s busy, budgets are tight, but you can’t afford to treat your compressor like it’s invincible. It’s not. And the cost of ignoring it is way higher than just doing the basics.

Lisa Saunders

So, let’s get practical. What can you actually do every day to keep your system running? There are four things—super simple, but they make all the difference. First, check your oil levels. Use the sight glass before you start up, and don’t skip those oil and filter changes. If you’re running in tough conditions—high temps, lots of dust—shorten your intervals. And don’t forget, even oil-free compressors need regular oil changes for the bearings and gears.

Jason Reed

Second, clean your drains and condensate traps. I know, it’s not glamorous, but if those get clogged, you’re either leaking air or letting water and gunk into your system. Either way, you’re risking damage to your compressor and your production equipment. Drain the water from your oil sump, too. It’s a five-minute job that can save you hours of headaches.

Lisa Saunders

Third, check for alarms. Most late-night calls to compressor techs are about alarms that got ignored. Sometimes it’s just a service interval, but if you don’t deal with it, you could end up shutting down for something that was totally preventable. And if you’re not sure what the alarm means, call your local service provider—they’ll help you figure out if there’s something else coming up, so you’re not hit with back-to-back shutdowns.

Jason Reed

And last, listen for new noises or vibrations. This is your early warning system. Grinding, rattling, weird hums—those are signs something’s off. Could be bearings, could be belts, could be misalignment. Don’t just crank up the radio and hope it goes away. Use tools like SPM meters or send out an oil sample for analysis. If you catch it early, you can fix it before it turns into a major failure.

Lisa Saunders

And honestly, this is where having a good relationship with your local, factory-trained distributor pays off. They know your system, they can spot issues before they get big, and they’ll help you schedule quarterly inspections. It’s way better to be proactive than to scramble when something breaks. We see it all the time—plants that invest in those relationships have way less downtime than the ones who just call in a panic.

Jason Reed

Yeah, and that’s the bottom line. Downtime prevention isn’t rocket science, but it does take discipline and the right partners. So, check your oil, clean your drains, pay attention to alarms and noises, and don’t be afraid to call in the pros. That’s how you keep your shop running and your costs down.

Lisa Saunders

Alright, that’s a wrap for today. If you want more tips, check out our previous episodes—we’ve covered everything from short cycling to pressure optimization. And if you’ve got questions, reach out to your local Kaishan distributor. Jason, always good talking shop with you.

Jason Reed

Same here, Lisa. Thanks for tuning in, everybody. We’ll catch you next time on The Big Dog Podcast. Stay sharp, keep those compressors running, and we’ll see you soon.