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How to know if my machine is working correctly?

Machines are like our own kids. If you work with them for a period, a bond develops between you and the Machine. And it will automatically know if something is wrong with the Machine. Well, that was an emotional way. If we talk technical, keep the Machine in observation, and if it's working correctly as before, then it's okay; otherwise, you have to look deep into the problem.

Any time a piece of industrial equipment works poorly, whether entirely or partially, or ceases to function as it should, it is referred to as a "machine failure" or "equipment failure." The phrase "machine failure" can refer to various situations and degrees of severity.

Failure, in this perspective, involves any loss of use inside a machine in addition to those essential show-stopping problems that completely cease production. The tolerance level for machine breakdown will change depending on the situation since all systems age and become less effective in some way. Even seemingly little reductions in usefulness might result in massive resource waste over time. For our purposes, a machine failure is any fault that prevents an industrial piece of equipment from fully or partially performing its tasks.

Causes of Equipment Failure and their Solutions

Here are some causes which can be caused of system failure with their solution:

  • Incorrect Operation

  • Inadequate Preventive Maintenance

  • Failure to keep equipment under constant surveillance

Incorrect Operation

Several persons may regularly be in and around essential equipment, substantially influencing its overall operational condition.

One such group is equipment operators. They are often given extensive training on suitable operating methods and basic troubleshooting, including best practices for safe equipment usage applicable to the machinery they will be working with. However, there may come a time when an operator is forced to operate on a machine for which they have yet to receive enough training. This circumstance might occur as a result of insufficient personnel or unexpected absences. Other times, events arise that necessitate speedy resolution using available personnel who may not have the skills that your most experienced teams do.

One strategy has enough qualified operators to provide flexibility during personnel shortage scenarios. Workers should be trained on every piece of equipment, even assets with which they are unfamiliar.

Most essential, never let an operator operate the equipment they are not qualified to perform. Not only will this assist in eliminating operational mistakes, but it is also required for regulatory compliance in several businesses. The Occupational Safety and Health Administration (OSHA) establishes criteria for operator training for specific types of equipment and general occupational safety. It is up to you, though, to be aware of the legislation that applies to your business and to ensure that proper compliance processes are in place.

Inadequate Preventive Maintenance

Most equipment necessitates regular care for optimal operation, but preventative maintenance is generally the first item to go when you're short on employees and overburdened. When things appear to be going smoothly, it's tempting to disregard routine maintenance, and many businesses assume that experienced staff would detect potential problems before total equipment breakdown.

Failures in equipment are challenging to identify and frequently go undiscovered. In other circumstances, businesses need more effective planning procedures to ensure continued maintenance. Using asset tags to track equipment and machinery helps keep maintenance plans on track and equipment working at peak operational efficiency.

Preventive maintenance is a continuous activity that should always be noticed. Regular tune-ups will increase the useable lifespan of your equipment, providing you with more value for your money. Furthermore, preventative maintenance may detect minor issues and provide affordable fixes before they become large, costly failures. Equipment downtime for regular maintenance and repairs is minimized when you employ efficient inventory control tactics to guarantee that you have the correct replacement parts in stock for the most frequent maintenance activities and failures.

Excessive Preventive Maintenance

So, how can you strike the perfect balance between preventative and corrective maintenance? The solution is simple but more challenging to implement: condition-based care. Instead of setting it and forgetting its' schedule, it is the upkeep that is performed based on the operational status of a piece of equipment. It considers various factors, ranging from manufacturer information to equipment histories to real-time data such as vibration analysis.

Continuous monitoring uses sensor data to create a baseline for optimal equipment conditions to identify tiny changes that may be utilized to forecast breakdowns and failures. This gives you more time to plan for contingencies and schedule downtime to minimize production interruptions. This form of monitoring, and the data generated as a result, may assist businesses in identifying the reasons for increasing stress on equipment and adjusting workloads and plans to prevent asset breakdown.

Final Words

When humans make mistakes, parts wear out, and maintenance work is neglected, equipment fails. However, by providing comprehensive operator training, doing preventative or condition-based equipment maintenance at the appropriate time, and working toward optimal operation and a better general culture, you'll have a greater chance of keeping your equipment in excellent shape.

Author: Talh'a Nadeem


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