Machine and equipment breakdowns are always costly, especially so for businesses that need to keep their production running 24/7. The impact caused by unexpected machines and equipment breakdowns can range from something that’s easily fixed with minimal loss to something more catastrophic. All of this depends on factors such as total downtime, repair costs, health and safety implications, and impact on production and delivery of goods.
Unexpected equipment failure can be hectic and frustrating. Not only is there an out-of-service machine that needs to be taken care of but also time lost and productivity to make up for. Today we’ll highlight some of the ways in which overworked machines can affect your overall productivity and how you can prevent it with CloudApper CMMS.
Overworking a Machine
Naturally, you will only want to get the most out of your machines because each piece of equipment in your facility is an investment. Constantly running your equipment at full capacity will eventually cause breakdowns sooner than expected. That is because maximum performance puts a strain on equipment. Always running machines at full capacity may not be the best option and can cause more trouble than benefits if they break down.
Here are a few things that can occur as a result of overworking your machine.
Machines are not magical equipment. When machines run continuously, they are bound to get overheated at some point. And without break periods, this might cause the machine to malfunction or not perform at its optimal (or acceptable) level. Overheated machines can reduce the effectiveness and life span of oils in the system as well as prematurely degrade important components like hoses and seals.
If your machines are frequently overheating, there might be an underlying cause that may not always be obvious. The best way to prevent heat loads is to ensure that all the features of the system, like oils and seals, are in top condition.
Of course, that means changing fluids, seals, and other critical parts of the system when they begin to degrade or otherwise go bad. It is also essential to perform routine inspections to identify problems before they become something that can halt your entire operation. Keeping a regular cleaning and maintenance schedule is also a must. All of these processes can be streamlined using a CMMS.
Faster wear and tear of components
No machine component or piece of equipment is immune to the physical stress of continuous operation. Wear and tear will eventually happen from repeated use of heavy machinery, even when machines are not pushed to their limit and their users follow best practices for machine longevity. Generally, wear and tear is a slow process that occurs over a significant period of time as opposed to a single, stressful event. Lubricants may wear off of moving parts, treads and tires may start wearing down, or the engine belt or bearing can face accumulated stress over time that will cause eventual failure.
Part of a larger risk assessment strategy involves routine inspections that can limit the wear and tear of machines. Managing wear and tear effectively involves a mix of maintenance tasks and bringing in specialized technicians when required. Preventative maintenance tasks can also help identify small issues before they become major, ultimately reducing the likelihood of unexpected total failures.
Loss in productivity
In many manufacturing processes, each unit is dependent on another, waiting for finished/semi-finished goods to be delivered to complete the process. If a piece of equipment unexpectedly breakdown, it can likely put a halt to production, ultimately leading to loss of time, money, and resources. Unexpected equipment breakdowns from overworking them also pose safety hazards to workers. A severe accident may occur if the worker is near the machine when it malfunctions. Either way, machines should not be overworked even if you would have made a few more bucks.
Prevent unexpected failures with good maintenance practices
There are times when you may be tempted to overwork your machine to meet a quota, make up for lost time, or make a few extra bucks. However, it’s not worth the risk.
Keeping machines in good working order is essential to maintain efficient and effective production. All machines in your facility require unique and specific maintenance tasks on a regular basis. Ignoring inspections or neglecting to tend to any of a machine’s components can cause the machine to break down earlier than expected. It can also prevent you from noticing emerging problems.
There are also some basic upkeep procedures to keep your equipment running smoothly and operating as expected such as lubrication application and tightening some parts every now and then. Worn-out components should also be replaced. Maintaining all these tasks can be difficult on pen and paper. To simplify your maintenance activities, you can rely on computerized maintenance management systems (CMMS).
CMMS help to streamline maintenance tasks. You can schedule maintenance tasks, document equipment service and inspection details, and store warranty dates all in one place. CMMS helps maintenance managers schedule tasks from their mobile devices and allows technicians to view these requests on the go.