In a perfect world, manufacturing equipment would operate as productively on day 1,000 as on day 1. 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. 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. Machine 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 and increase operating costs.
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: It is paramount that operators 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, he or she 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 preventative 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.
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 the malfunction of equipment 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 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.
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 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. If you need assistance putting the right plan in place to prevent unplanned downtime, contact us today!
