When any form of industrial failure occurs, it leads to 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 failure as it can give you time to prepare for the damage. So here are the 4 most common causes of industrial machinery failure –
Lack of Proper Maintenance
It is one of the most common reasons for failures in industrial equipment and machinery. Lack of maintenance is like going running without any energy. You will run for a distance and turn to walk, and eventually stop it altogether.
Every fillable like oils, lubricants, fuel should be regularly maintained. 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, and fault detection, along with lubrication, must all be a 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 all forms of mechanical wear and tear. Metal fatigue, rough joints because of abrasion or adhesion because of lack of proper lubrication are common results of overloading the machinery.
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. When replacing a defective or damaged part, always check the linked parts for damage as well.
Lack of Training or Improper Handling
Human-made accidents are always preventable. Giving proper training on how to maintain, check and operate the machinery can save the 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.