Beyond the obvious headache and compromised safety, equipment failure is usually followed by costly repairs, delays, and loss of productivity. Some breakdowns are bound to happen, and there’s nothing you can do. Others however, could be prevented, given there’s regular maintenance involved.
To keep things running smoothly, many different things have to work in sync (e.g., hydraulic systems, motors, pumps, electrical components, etc.); it all needs to be in top-notch shape. And if routine checks and servicing are being neglected, then those breakdowns that could have been prevented will undoubtedly cause chaos.
If that doesn’t sound too great, you’ll want to keep reading, because in this article, we’ll take a peek at the most common equipment failures, and what we could do to prevent them from happening.
5 Common Equipment Failures and How to Prevent Them
To keep equipment from breaking down, you have to maintain it on a regular basis. Here’s what the most common failures are and how to keep them at bay.
- Hydraulic Leaks
This is one of the most common and one of the most problematic failures in industrial equipment. They happen when there’s a break in the hydraulic system, which can result in loss of fluid, reduced performance, and it can damage to the machine itself. Leaks usually slip under the radar until they cause some serious problem, like a malfunction or complete breakdown.
Prevention starts with regular inspection. Check for any signs of leaks, including oil stains and drops. You should also use proper sealing techniques and check that all hose connections are tight and intact.
- Pump Failures
Pump failure can cause the entire operation to stop, especially in industries where pumps are used for fluid movement or circulation. A failed pump means that no fluid is being moved, which can disrupt the whole system. This typically happens because the parts get worn out, fluid levels are low, or contamination.
To prevent it, you should keep an eye on oil and fluid levels and see if the pump is operating efficiently. It’s also smart to replace hydraulic pump parts that show signs of wear before they fail.
- Valve Failures
Valves are key in controlling the flow of fluids in hydraulic systems, and when they fail, it usually affects the entire system. A malfunctioning valve can disrupt the flow of fluid, which leads to problems with pressure, reduced efficiency, and even a total shutdown. Failures of this kind are mostly caused by dirt or debris entering the valve, improper handling, or wear and tear over time.
Prevention is not complicated at all. Just make sure to clean the valves o a regular basis and recalibrate them to keep them working correctly. It’s also important to handle them properly during maintenance; if you’re too rough, you could cause damage that leads to malfunction.
- Motor Failures
Motors are the heart of many machines and when they fail, that’s a huge problem. They can fail for all kinds of reasons, but the most common ones are overheating, electrical issues, or wear from overuse.
The first step in preventing these expensive failures is to keep the motor free from dust and debris. Buildup can interfere with motor function and cause overheating. Check the bearings and lubrication points to make sure things are running smoothly. Maintenance is pretty straightforward and if you keep up with it, you’ll significantly reduce the risk of motor failure and improve the longevity of your equipment.
- Electrical Failures
Electrical failures can affect all types of equipment because most industrial machines need electricity to function. A malfunction in the wiring or an electrical component can cause a system to fail or even result in a dangerous situation, like a short circuit or a fire. In fact, close to 16% of all structure fires in the U.S. are caused by faults in wiring.
To prevent electrical failures, you should regularly inspect electrical systems and see if there are any cables that have frayed, loose connections, or signs of overheating. Also, test electrical systems and check that they’re grounded properly. If you catch any issues early, you have enough time to handle them before they cause a world of damage or even injury.
Conclusion
If you work with machines, it’s only natural that they break sometimes. And while it’s again natural to fix them so that they return to operation, it’s also more ideal if that break never happened in the first place.
Some good old preventive measures, such as regular maintenance and routine checks, will do wonders for the longevity of your machinery. It’s pretty much the same as with us humans – we also need to undergo checkups from time to time. Also, your car, you’ll surely take it to the mechanic to ensure everything is running smoothly. Well, your equipment deserves the same type of attention, too. And if you provide it, you’ll be rewarded with fewer issues and breakdowns.