Any manufacturer out there can pay dearly for downtime and defects. Plants thrive only when they can turn out the right amount of quality units. Experienced, reliable staffing in manufacturing operations certainly counts, but a lot of our troubles really come down to the equipment we use. Here are five common causes of malfunctions, and how we can avoid losing time and money because of them.
1. Improper operation.
Did you ever stop to think that the way you use your equipment, while more efficient for your purposes, has long-term impacts on the machine? We get used to operating it one way, and forget that perhaps this isn’t how it was intended to be used.
To fix this, begin reading manuals and any other materials you can get on the equipment you use. When you’re aware of the finer details pertaining to proper use, fewer errors and breakdowns will occur.
2. Lack of maintenance.
It sounds fine and runs well…until it doesn’t. Anyone who touches or observes your equipment on a daily basis should be apprised of maintenance guidelines. You should also refer to the equipment manufacturer’s guidelines on how often more comprehensive maintenance should be performed.
Replacing parts is key as well. Check out Plano Power and replace what you must — if you don’t, this can impact the health of adjacent parts.
3. Electrical malfunctions.
Hopefully, when your equipment fails, it doesn’t result in a shower of sparks, or a fire. Unfortunately, this is what improperly maintained or very old equipment can do when electrical connections, switchgears, and distribution transformers are on the fritz.
The first course of action in preventing this is to have your equipment checked regularly by a professional with electrical expertise. Your equipment needs to remain safe and compliant if you want to continue producing.
4. Communication.
People who have never worked in manufacturing often believe that the machine does all of the work. In reality, the number of tasks involved in turning out a good unit, and how it all comes together during assembly, can be much more involved than the layperson imagined.
If one link in communication is dropped, the production suffers, and some of these lapses can result in equipment failure. Make your staff feel like a team, and everyone’s more likely to stay motivated and on the same page when it comes to fast, high-quality production.
5. Overuse.
How much are you asking from this one piece of equipment? If you are pushing it to the limit during all operating hours, breakdown is inevitable. For starters, constant higher modes of operation can cause early wear and misalignment, which lead to a whole range of problems.
In some cases, it may be best to replace the equipment. Many expect to do so when they know they’ll be using a machine to its absolute maximum potential.
Your equipment makes your money, so start thinking seriously about making a greater investment in its safety and reliability. Consider how it’s operated, minimize breaks in communication, and always, always pay close attention to inspection and maintenance. Repairing and replacing parts before it’s too late will always be more affordable than having to purchase an entirely new machine.
