Mechanical breakdowns in industrial machinery are commonly associated with problems arising during design, production, or use and upkeep.
Yet, these scenarios share a common thread: these breakdowns often occur prematurely because of disregard for established preventive measures or insufficient use of appropriate techniques and equipment.
Hence, it is crucial to integrate preventive measures at all stages of a machine’s life, from design to operation, and to detect and address these issues promptly through automated diagnostics. Homeowners can also follow similar principles to identify and prevent mechanical failures in their household appliances and equipment.
Here’s how.
Improper Operation
Numerous individuals could influence the overall operation of critical equipment and are often near it daily.
One such group includes equipment operators who undergo comprehensive training in proper procedures, basic troubleshooting, and safety practices for their operating machines.
Despite this, instances may occur where an operator has to work on unfamiliar machinery due to staffing issues or unexpected situations. In such cases, quick action may be needed from available staff who may not possess the same level of expertise as the most experienced operators.
One approach is to ensure an adequate number of trained operators to handle emergencies caused by staff shortages. Ideally, all operators should receive training on every piece of equipment, even those they do not usually operate.
High-quality v-belts, bearings, and other common wear parts should be stocked for replacement in an emergency. Additionally, detailed operation manuals must be available to all operators at all times.
Skipping Preventive Maintenance
Most equipment needs regular maintenance for top performance, yet preventive maintenance is often neglected when short-staffed. It’s common to overlook maintenance when everything seems fine, with companies banking on experienced staff to catch issues early.
Equipment failures can be hard to spot, and sometimes companies lack effective maintenance planning. Using asset tags to track equipment can aid in staying on top of maintenance schedules for maximal efficiency.
Preventive maintenance should always be a priority. Consistent tune-ups can prolong equipment life, saving you money. It also helps catch small issues before they escalate into costly breakdowns. Efficient inventory control ensures you have spare parts on hand, reducing downtime. The U.S. Department of Energy reports that preventive maintenance can lead to:
- Up to 30% lower energy and maintenance costs
- 35% to 45% fewer breakdowns
- Up to 75% less downtime
Don’t Overload Your Washer and Dryer
Washers and dryers have weight limits for good reasons. If you stuff a front-loading washer or dryer too full, you might end up shelling out a lot to replace a drum bearing or motor. Exceeding the limit in a top-loading washer could lead to small items floating up and getting stuck in the pump. It may also cause damage to the drive coupler and drive belt.
An overloaded dryer doesn’t just prolong drying time! It can cause wear on the drive belts and drum support rollers, which are expensive to replace.
For safety, refer to your owner’s manual to find out the weight limits for your units and make sure not to go over them.
Clean Your Refrigerator Coils and Gaskets
Vacuum the coils underneath or at the back of your refrigerator every six months. Accumulated dust can reduce airflow, leading to extended and hotter operation of the compressor and condenser fan.
Cleaning the condenser coils is a straightforward task.
- Utilize a vacuum to eliminate dust and pet hair.
- Unplug the refrigerator or switch off its circuit to avoid the risk of electric shock.
- Reconnect your fridge or switch the circuit back on.
If you have pets, consider doing this maintenance two to three times annually.
Also, remove any syrup, jelly, honey, or sticky residues from the door gasket. Residues might hinder proper door sealing and potentially cause gasket damage when opening the door. These simple maintenance activities could save you significant money: A replacement compressor may cost up to $600, a new condenser fan might cost up to $250, and a fresh gasket can range from $150 to $300. In severe cases, replacing the entire appliance could become necessary.
Endnote
Equipment failure occurs due to human errors, aging components, and neglecting preventive maintenance.
However, by providing proper operator training and scheduling preventive or condition-based maintenance at the appropriate times, you can significantly improve the chances of maintaining your equipment in excellent condition.
