When any form of industrial failure occurs, it leads to a loss of money, time, and production for the company. It affects every process that is interlinked with that particular machinery. The value of the loss can be catastrophic depending on the size of the machinery. And at worst, if the failure goes unnoticed, it can lead to life-threatening accidents.
The factors that prevent failures are proper maintenance, regular checks, following instructions, and proper training. It always helps to know the most susceptible points to collapse, as it can give you time to prepare for the damage. So here are the four most common causes of industrial machinery failure –
Lack of Proper Maintenance
It is among the most common reasons for industrial equipment and machinery failures. Lack of maintenance is like going running without any energy. You will run for a distance and turn to walk, and eventually stop altogether.
Every fillable should be regularly maintained, like oils, lubricants, and fuel. Similarly, the parts and the frames should be checked for cracks, leaks, or squeaks. All in all, a proper preventive maintenance plan should be prepared and strictly followed at all levels. Inspection, adjustments, replacements, repairs, fault detection, and lubrication must all be part of the maintenance process.
Overloads and Straining
To keep the supply running, many industries keep their machinery running continuously without any breaks. Taking the machines over their limits can lead to mechanical wear and tear. Metal fatigue and rough joints due to abrasion or adhesion due to improper lubrication are common results of machinery overloading.
Wear and tear of one part will slowly affect the other components, and eventually, the whole process is in danger of downtime or serious accidents. After the failure has taken place, only a mechanical failure analysis can reveal what could have been the reason for the fall.
Obsolesce or Non Replacements
Machines deteriorate, and there’s nothing to debate about it. But using the same machinery in an important, expensive process is debatable. Unless you are using some advanced predictive method to keep the part under monitoring, there’s no way you can know when it fails. And a breakdown at any step of the process can lead to downtimes and loss of resources.
Similarly, replacing only the broken parts is a temporary fix that can cost money in downtime. Replacements at the right time are crucial for any industrial process. Always check the linked details for damage when replacing a defective or damaged piece.
Lack of Training or Improper Handling
Human-made accidents are always preventable. Proper training on maintaining, checking, and operating the machinery can save time and money lost because of accidents. Time invested in training can make your machinery last longer.
If there is new machinery on the premises, take time to train about its use and maintenance. Also, inform them about the potential dangers of mishandling and negligence.
