5 Ways manufacturers can strengthen operations during downtime

Wednesday, July 23, 2025

Close-up of rotating metal gears, symbolising continuous improvement and strategic operations during downtime.

Downtime can be a mixed blessing for discrete manufacturers. On the one hand, it means reduced activity – factory shutdowns, staff on annual leave, and quieter suppliers. On the other, it offers a valuable opportunity to get ahead, both operationally and strategically.
With the final quarter often being the busiest of the year, a slower period is the perfect moment to plan ahead, optimise resources, and invest in internal improvements. Here are five practical ways manufacturers can use that time to strengthen operations.

1. Adjust production schedules to match staff availability

Staff availability is usually tighter in the summer – whether due to annual leave or factory closures – so visibility into your team’s capacity is critical. Effective planning means you can schedule production more efficiently, avoid bottlenecks, and maintain service levels even with fewer people on the floor.
Start by reviewing upcoming shifts, planned absences, and skills across your workforce. Use this to adjust workloads, flag shortages early, and plan for cross-coverage or temporary support if needed.

2. Get ahead of supplier delays before they happen

It’s not just your team that slows down in the summer – many suppliers reduce operations or alter delivery schedules. That’s why it pays to be proactive.
Use your historical data to forecast demand and identify where you might need buffer stock. If you work with just-in-time deliveries, now’s the time to double-check timelines and set alerts for any delays. Communication is key: a quick check-in with your core suppliers could prevent last-minute surprises.

3. Use quiet periods for maintenance and optimisation

Lower production volumes provide a rare window for internal improvements. That could be scheduled maintenance on machinery, reviewing processes, or trialling new tools and systems.
Think of it as a chance to fine-tune your operation. Planned maintenance can be integrated into your production schedules to reduce disruption, while system updates or small process changes can be tested with minimal risk – all setting you up for a stronger Q4.

4. Develop your team while it’s calm

When things are busy, training tends to be put on hold. But summer is the ideal time to revisit team development. Whether it’s technical skills, compliance training, or getting new starters up to speed, this is a smart way to boost productivity and flexibility across your workforce.
Identify key knowledge gaps or areas where cross-training could help. If you use digital tools or ERP software, consider creating internal ‘super-users’ who can help spread best practices when things get busier.

5. Forecast with confidence to prevent q4 surprises

Demand forecasting is always important – but it’s especially crucial during unpredictable periods like summer. Use sales, production, and inventory data from previous years to spot trends and plan with confidence.
Forecasting tools can help you balance supply and demand, keep inventory levels in check, and ensure your staffing plans match anticipated workloads. And if you're operating with fewer staff, automation can play a big role in reducing manual admin and keeping key tasks moving.

Small Tweaks Now, Big Payoffs Later

While summer may feel like a lull, it’s actually a strategic time to strengthen your foundations. From smarter planning to smoother supplier relationships and better-trained staff, the actions you take now can give you a real advantage when business picks up in Q4.

If you’re looking for ways to streamline these efforts – from planning and forecasting to supplier coordination and training – modern ERP systems can help bring all of this together in one place.