In a perfect world, manufacturing equipment would operate as productively on day 1,000 as on day one. Unfortunately, that’s rarely the case. Manufacturers always need to be on guard for the possibility of equipment failures because of the impact they can have on productivity and ultimately the bottom line. Because prevention is often the best cure, it’s necessary for operators to understand what causes machine failures in the first place so they can take steps to keep them from happening.
Unplanned downtime costs manufacturers an estimated $260,000 per hour, according to Aberdeen. That level of financial risk highlights why it’s not just equipment repair that matters — it’s equipment reliability. Proactively preventing issues through preventive maintenance tasks, training, and predictive diagnostics helps avoid safety hazards, productivity loss, increased costs, quality defects and long-term wear.
Read on to learn more about what causes machines to malfunction and what can be done to prevent downtime.
Understanding equipment failure
The most troublesome and severe machine failure examples occur when the equipment shuts down entirely, which means it can’t perform any function. However, it’s important to note that partial failures can have just as much of a negative effect on productivity. Even if just one component breaks down, it can cause a domino effect that can have serious repercussions. A machine that operates at diminished capacity can be as damaging to a manufacturing operation as one that doesn’t work at all.
The interconnected nature of the modern manufacturing environment means any broken links in the chain can lead to big problems. Equipment failure can shut down production for an extended period, but this is not the only potential consequence. Malfunctioning equipment also can create safety hazards for workers, increase operating costs and introduce product quality issues that affect customer satisfaction.
In some cases, partial failure can mask deeper issues, including equipment malfunction due to undiagnosed stress or fatigue in critical components. Left unchecked, this can escalate into full-blown mechanical failure that brings operations to a standstill.
Common causes of equipment failures
Machinery malfunctions don’t just happen spontaneously — they’re always the result of some action or inaction that creates the conditions for one or more elements to stop working as intended.
Some of the most common causes of failing equipment include:
Lack of preventative maintenance: Ideally, technicians should be inspecting machines on a regular basis and performing any lubrication, part replacement or other actions to keep them in good working order. Without a solid plan for providing preventive maintenance services throughout the facility, minor issues can snowball into major faults that can shut down the entire system.
Operator error: Operators must be fully trained in the proper procedures for using all equipment. Any improper usage can lead to undue stress and strain on components, which can result in machinery breaking down. If someone is not fully qualified to operate a specific piece of equipment, they should not be allowed to use it.
Wear and tear: Nothing lasts forever — even manufacturing equipment designed to be as robust and durable as possible. Over time, the long-term effects of usage can wear away components and bring them closer to the end of their natural lifespan. Without proper maintenance and care, this wear can lead to these elements breaking or becoming unable to perform their functions.
Environmental factors: Manufacturing machinery doesn’t exist in a vacuum — factories and production plants are often harsh environments where moisture, grit and caustic vapors are found. These factors can take their toll on equipment over time, causing parts to corrode, wear down or become encrusted with dirt. This is yet another reason why regular maintenance that includes cleaning and lubricating machinery is vital for the health of any manufacturing plant.
Over-maintenance: It may sound counter-intuitive given the emphasis placed on preventive maintenance, but over-maintaining equipment can hasten its deterioration. This is far less common than other causes, but no less impactful. Without data-driven insights provided by machine health monitoring and other solutions, there’s a danger of putting too much work into machines and disrupting systems. It’s just as important to know when to maintain equipment as it is to know how to do it.
Poor installation or setup: Even high-quality equipment can fail prematurely if it’s not installed correctly or calibrated to spec. Misalignment, improper torque on bolts or skipping commissioning steps can lead to excessive vibration, heat or part stress from day one.
Inadequate lubrication or contamination: Lubrication issues are a leading cause of bearing and gear failures. Too much lubricant, too little lubricant or contaminated lubricant (e.g., with dirt, water, or metal particles) can increase wear and heat, shortening component life.
Deferred maintenance or budget constraints: Skipping maintenance cycles to save time or cut costs often backfires. Deferred work can allow small issues (like a worn belt or misaligned pulley) to escalate into complete system failures.
Software/control system failures: In highly automated environments, software or control system glitches can cause improper signals, false alarms or incorrect operation sequencing — which may damage equipment.
Special risks with heavy equipment: Larger industrial assets like cranes, dozers and excavators are more complex and more costly to repair. Heavy equipment is also exposed to more intense operating conditions, requiring additional attention to lubrication, vibration analysis and timely replacement of wear components.
Some causes — such as environmental stress and wear — happen gradually and predictably. Others, such as poor installation or a single missed maintenance task, can trigger sudden breakdowns. High-frequency issues may be easier to plan for, but low-frequency, high-severity events can be far more disruptive. A comprehensive maintenance management strategy accounts for both.
How to prevent equipment failures
Once the causes of malfunctions are understood, the next step is to enact a plan for preventing them. Some of the best ways to avoid equipment breakdowns in a manufacturing setting include:
Implementing preventive maintenance: Creating a regular schedule for maintenance based on root cause failure analysis can help stop most malfunctions before they start. By getting out in front of wear and tear as well as the effects of environmental conditions, manufacturers can keep their machinery in good working order for as long as possible and extend its lifespan to a significant degree.
Predictive maintenance: The rise of the Industrial Internet of Things (IIoT) has given technicians another crucial tool for preventing machine failures in the form of predictive maintenance technology. Harnessing the power of big data and advanced predictive analytics, they can pinpoint when certain elements of their systems can be expected to break down and focus their attention there before any problems develop.
Proper training and education: Implementing a good program for industrial maintenance training and appropriate equipment usage helps ensure machines remain in good condition. Without a workforce fully trained in good behaviors and the proper protocols, even the strongest plans are nothing but words in a manual.
Monitoring environmental conditions: Industrial environmental monitoring is an essential element of preventing breakdowns. With sensors providing a constant stream of information about what’s going on in and around machines, technicians can be on the lookout for any potential signs of trouble to come.
Quality control in design and manufacturing: Having the right procedures in place for ensuring quality control in manufacturing can reduce unnecessary wear and tear on equipment and help preserve it for much longer.
Using a CMMS: A Computerized Maintenance Management System (CMMS) can greatly improve maintenance scheduling and record-keeping. A CMMS streamlines task tracking, technician assignments, parts inventory and condition-based maintenance routines, which helps keep everything centralized and easy to audit.
Conducting failure analysis: Identifying the root cause of past breakdowns and understanding trends over time allows companies to refine their strategies. Techniques such as FMEA (Failure Modes and Effects Analysis) and RCA (Root Cause Analysis) help avoid repeat failures.
The hidden cost of downtime and failures
When equipment fails, the obvious costs include repair bills and replacement parts. But the hidden costs — like lost revenue, missed deadlines, and wasted labor — often dwarf those initial figures. Downtime affects productivity, quality and profitability. Even worse, it places stress on the maintenance team, delays other maintenance tasks and diminishes technician bandwidth for high-priority improvements.
The full consequences entail:
- Lost revenue from halted production
- Delayed shipments and dissatisfied customers
- Emergency overtime labor expenses
- Decreased morale due to firefighting vs. high-value work
Studies have shown that manufacturers who adopt predictive maintenance and advanced planning tools can reduce total maintenance costs by up to 10% while improving uptime and overall equipment performance. When maintenance is viewed as a strategic function rather than a reactive cost center, its value multiplies.
Ready to prevent equipment failures?
A machine that breaks down in the middle of the manufacturing process is more than irritating. It can cause a chain reaction that results in lost production, excessive costs, unsafe working conditions and ultimately long-term harm to a company’s profitability. This is why being able to identify and mitigate the most common causes of machine malfunctions is so important for manufacturers.
Keeping up with equipment maintenance, training employees and leveraging advanced technologies are all crucial strategies for preventing the worst-case scenarios. With the right plan in place, manufacturing operations can keep running as smoothly as possible and prevent the kinds of disasters that lead to trouble.
ATS supports manufacturers through:
- Surge technical staffing
- Condition monitoring and predictive diagnostics
- CMMS consulting and deployment
- Maintenance management software solutions for tracking and scheduling
If you need assistance putting the right plan in place to prevent unplanned downtime, contact us today.
References
Arsenault, R. (2016, April 21). Stat of the week: The (rising!) cost of downtime. Aberdeen Strategy & Research. Retrieved from https://www.aberdeen.com/blogposts/stat-of-the-week-the-rising-cost-of-downtime/
Coleman, C., Damodaran, S., Chandramouli, M., & Deuel, E. (2017, May 9). Industry 4.0 and predictive technologies for asset maintenance. Deloitte Insights. Retrieved from https://www.deloitte.com/us/en/insights/industry/manufacturing-industrial-products/industry-4-0/using-predictive-technologies-for-asset-maintenance.html
