Downtime and operational inefficiencies in highly regulated industries translate to substantial financial losses and regulatory risks. What can you do to address these challenges?
With inflation and rising supply costs, manufacturers reported a 50% increase in unplanned downtime expenses in 2022 compared to 2019-2020, according to a Senseye report.
A shrinking talent pool and aging workforce are straining industries like energy, oil and gas, and food production. Fewer skilled technicians mean longer downtimes, higher costs, and compliance risks. Delays, waste, and customer dissatisfaction follow. To stay competitive, companies must embed expert support and streamline parts management—it's no longer optional.
Swanson Flo, an MCE company offers tailored services and expertise to address these challenges.
4 Key Impacts of Workforce Shortages on Downtime and Operational Efficiency
Increased Downtime: Highly regulated industries rely on skilled technicians to maintain and troubleshoot complex systems while ensuring regulatory compliance. Limited expertise can lead to delays in diagnosing and resolving issues, prolonging downtimes.
For instance, imagine a valve goes bad in an oil refinery; that repair could take twice as long due to a lack of expertise—costing millions in production time, environmental impacts and fines, and potential legal fees.
Overburdened Staff: Companies often over-rely on existing employees to compensate for vacant positions. This can lead to burnout, safety incidents, and operational mistakes.
Ineffective Preventative Maintenance Programs: With limited staff, the focus shifts from prevention to reaction, significantly increasing the risk of unplanned downtime.
Insufficient Training for New Hires: New employees may struggle to meet safety and compliance standards, leading to delays and shutdowns.
Solutions to Mitigate Workforce Challenges and Reduce Downtime
Labor shortages are more than an HR issue—they directly impact uptime, operational cost, and safety compliance. MCE addresses these challenges through:
Expert Onsite Technicians for In-House Repair
We offer region-based full-capability service and repair, backed by 50+ years of experience.
- Comprehensive Repairs: Onsite/mobile services for valves, instrumentation, actuators.
- Valve Automation: From pneumatics to fully automated valve systems.
- Precision Compliance: Work is performed to industry standards, reducing risk.
Proactive Critical Spare Inventory Management
We partner with vendors to support a full product lifecycle and carry a wide range of flow control products, including:
- Actuation & Accessories
- Control Valves
- Process Valves
- Protective Solutions for Instruments
We also offer vendor-managed inventory (VMI) services. With centralized stocking, MCE ensures quick access to critical components.
>> Learn how MCE’s VMI program reduced one manufacturer’s inventory management time by 80%
The MCE Advantage: Precision, Performance, Perfection
MCE and Swanson Flo have a strong track record in automation and service delivery. We help engineers and maintenance teams optimize performance through:
MCE Precision and Expertise
- Instrumentation Calibration: Traceable NIST calibrations.
- Control Valve Repair Programs: Rebuilds, leak testing, welding.
- Diaphragm Seal Assembly: Certified testing for transmitters/gauges.
- Turnaround Support: Onsite support during shutdowns and emergencies.
- Critical Spares Access: Same-day repairs and emergency shipping.
- Phone Support: Remote diagnostics and guidance.
Certifications
- Limitorque Blue Ribbon Repair Facility
- Factory Authorized for Schneider Electric (Foxboro)
- FM Certified for Flowserve Limitorque
- NIST-Traceable Calibration Equipment
With 80%+ of repairs conducted in-house, MCE offers a fast, cost-effective alternative to factory repairs—helping you minimize downtime and maximize compliance.
MCE Customer Successes in Action
Ensuring Conductivity Meter Calibration for Food Processing Compliance
An egg processing plant relied on MCE-Swanson Flo for conductivity meter calibration used in CIP systems. Our solution included scheduled onsite checks, NIST-traceable tools, real-time recalibrations, and thorough documentation. The plant passed inspections, avoided downtime, and continues to partner with us annually.
Reducing Oil Refinery Failures with Preventative Maintenance
A refinery experienced frequent actuator failures. We implemented annual preventative checks—cutting down failures and saving millions in repair costs and lost production.
Streamlining Ethanol Plant Restarts
Our technicians supported ethanol plant restarts over five years, preventing at least three unplanned shutdowns. Services included turnaround calibration, custom transmitter/actuator solutions, and emergency support.
Why Partner with MCE and Swanson Flo?
MCE bridges labor and supply chain gaps with embedded technicians, reliable inventory management, and proven expertise.
- Knowledgeable Support: Deep expertise in key industrial sectors.
- Onsite Repair: Mobile trailers, vacuum chambers, and fast service.
- Access to Critical Spares: Same-day repairs and shipping.
- Scheduled Preventative Maintenance: Proactively reduce failures and downtime.
With 50+ years of experience and a robust service network, MCE-Swanson Flo helps customers boost uptime, stay compliant, and operate with confidence.
Contact us to learn how Swanson Flo can support your operations.
