Equipment Failures Can Cause Major Problems; Here’s How To Prevent Them

Introduction

Equipment or machine failure refers to instances where industrial machinery fails to perform as intended, ranging from minor disruptions to catastrophic malfunctions that halt operations entirely. Examples include engine failures, brake malfunctions, interruptions due to thermal conditions, electronic defects, power failures, and fuel supply disruptions. Promptly addressing these issues through effective maintenance and proactive monitoring is crucial to minimize downtime and ensure optimal operational efficiency, safety, and productivity.

Experts use methods like root-cause analysis, fault tree analysis, and Layers of Protection Analysis (LOPA) to mitigate equipment failure risks. LOPA, conducted by an experienced facilitator, assesses the Safety Integrity Level (SIL) of protective instruments by breaking down scenarios and assessing individual risks to ensure adequate safeguards reduce the likelihood of failures.

It identifies potential failure scenarios, evaluates protection layers, and documents risk assessments, mitigation strategies, and safety system designs. This structured approach enables tailored actions such as enhanced maintenance protocols and equipment upgrades, which are critical for preventing equipment failures.

The Two Types of Equipment Failure

Equipment failure fundamentally occurs when equipment fails to perform as intended. This spans two primary categories, each bearing substantial consequences for operational efficiency and continuity: complete and partial failure.

Complete Failure

A complete failure represents a critical scenario in which equipment ceases to function entirely, resulting in immediate downtime and halting of operations. Instances of complete failure may include incidents such as vessel ruptures, engine malfunctions, or severe HVAC breakdowns, requiring prompt repairs or replacements to restore operational capabilities.

Partial Failure

Partial failure allows equipment to operate at diminished capacity or efficiency. Examples include machine malfunctions and motor control issues that cause reduced conveyor speeds or inadequate lubrication, increasing friction and wear.

Complete failures are easily identified due to their significant disruption to operations. Addressing partial failures promptly through proactive maintenance is crucial to prevent them from escalating into more serious issues. This approach mitigates their potential impact and ensures ongoing operational reliability.

Common Causes of Equipment Failure

Equipment failure can be unpredictable and influenced by various factors that lead to machine failure or reduced performance. Understanding these common causes is essential for implementing effective preventive measures. Here are some primary factors contributing to equipment failures:

Aging Machines

Aging equipment naturally degrades over time, increasing the likelihood of breakdowns due to wear and tear, bearing failure, corrosion, and surface deterioration. Poor conditions, inadequate maintenance, improper usage, and storage practices worsen these problems, potentially resulting in significant equipment damage.

Regular lubrication reduces friction and wear on rotary machines to mitigate these risks. Implementing routine inspections, preventive maintenance, machine inspection, and timely replacement of worn components such as belts, hoses, bearings, and filters is crucial to minimizing the risks of wear and tear.

Improper Use

Equipment failures often result from human error, which includes distractions, poor decisions, and procedural deviations despite training. Factors like forgetfulness, fatigue, and negligence contribute to operators misusing and abusing equipment, leading to failures such as accidental mishandling or equipment drops.

To prevent these issues, it is crucial to conduct thorough operator training, strictly adhere to manuals and checklists, and ensure all operators are proficient with their equipment. Regulatory compliance and proactive training are essential to minimize errors and uphold safety standards.

Inadequate Inspections

Many organizations experience equipment failures due to insufficient machine inspection and preventive maintenance, often because of budget constraints. Infrequent maintenance can allow unnoticed issues to escalate, while excessive maintenance risks damaging components or disrupting operations. Time-based preventive maintenance becomes less effective as equipment ages, leading to increased failure rates due to insufficient maintenance later in its lifespan.

Implementing asset tagging systems helps track maintenance schedules and ensure peak equipment performance. Regular tune-ups extend equipment lifespans and address minor issues early. Maintaining an inventory of spare parts reduces downtime for routine maintenance and repairs.

Consequences of an Equipment Failure

Equipment failure can have far-reaching consequences across various dimensions, affecting operations and stakeholders profoundly. Here are some significant impacts of equipment failure:

Halt in Production

Production may occasionally halt due to equipment failures or machine malfunctions, resulting in delayed product deliveries that impact supplier networks and consumer satisfaction. Moreover, these interruptions can have significant financial implications, potentially leading to fines for contract breaches.

Machine Repair or Replacement

The cost of repairing or replacing broken machines can be significant. This includes direct expenses, such as labor and components, and indirect costs, such as production losses, downtime, and the necessity for expedited orders to meet deadlines. This process is particularly challenging for older or specialized machinery, as locating replacement parts can prolong operational downtime.

Employee Injury

Equipment failures significantly jeopardize workers’ safety. Malfunctions in equipment, which can lead to potential electrical hazards and structural failures, pose serious risks, resulting in accidents ranging from minor incidents to severe or fatal outcomes. Each type of failure presents distinct dangers, such as electrical components malfunctioning and causing fires or shocks or machinery abruptly halting operation.

Environmental Damage

Equipment failures in industries handling hazardous products or large machinery can lead to significant environmental repercussions. For example, leaks or spills from malfunctioning equipment can contaminate land, air, or water sources, potentially causing lasting environmental harm and requiring extensive cleanup efforts. Such contamination poses serious threats to ecosystems and public health.

Public Disturbance

Equipment failures or machine malfunctions lead to delays, lower-quality production, or inconsistent performance, which can harm a company’s reputation and cause customer dissatisfaction. These disruptions inconvenience individuals and have broader economic repercussions for businesses and municipalities alike.

Preventing Equipment Failure

Conclusion

Equipment failures present significant challenges across industries, impacting operations, finances, safety, and the environment. Experts employ methods like LOPA to assess and enhance the SILs of protective instruments. These methods help identify potential failure scenarios, evaluate protection layers, and establish robust risk assessments and mitigation strategies. Additionally, the LOPA team should be led by an expert facilitator in California, USA, to increase chances of success.

Proactive maintenance, including regular machine inspections and predictive techniques, is crucial to prevent equipment failures and ensure ongoing operational reliability and safety. Adhering to these practices, organizations can minimize downtime, optimize productivity, and maintain their commitment to safety and environmental responsibility.

With expert LOPA facilitators in California, Saltegra Consulting LLC can help you implement proactive maintenance practices in your facility. Contact us for more information.