How to Reduce Machine Failure and Equipment Downtime

Many companies, small or large, create their value through just a few pieces of equipment.  These “machines” are often referred to as critical, bottlenecks, proprietary processes, and are sometimes built in house.  No matter the size, small or large, these machines failing or simply not operating in a correct fashion can result in loss of product, increase waste or off quality, and ultimately a financial hit. What is a way to mitigate this risk of critical machines failure? 

Common Reasons for Equipment Failures

There are several broad reasons for equipment failure.

Operator Run Errors

In some instances, the equipment operators are running the machines in a way that tears them up and leads to more machine downtime.  Setting up the machine to run product, change over, or on a startup is critical to have all run parameters, settings, and alignment to allow the machine to operate the way it is intended and designed to.  Many companies have experienced turnover in the recent months and years and have lost the “tribal knowledge” of those experienced operators.  Our new generation of operators are often thrown into the work environment with little to no training, no guides to how to operate the equipment, and no understanding of what to do in situations when the machine is not functioning (troubleshooting).

Risk Mitigation for Operator-Caused Machine Downtime

• Establish run parameters, clear work instructions, and have an OJT (on the job trainer) to review the performance against the documented work instructions.  This provides a handoff between tenured operators and new ones, creating confidence in the new operators.

Machine Break Down

Machines break down, but do they have to?  The simple answer is no.  With a sound PM (Preventive Maintenance) program companies can minimize the equipment downtime due to break downs and focus the time in scheduled down time.  Think of a pit crew in a race.  They change 4 tires, add fuel, clean the windshield and the air intake grate, and provide a drink to the driver in 14 seconds.  How do they do that?  Planning and practice.  Companies with an effective preventive maintenance program have planned downtime where the right amount of people take only the necessary time needed to replace broken and worn parts.  This is usually a fraction of the time that would normally happen than with a run to failure mindset, where companies run the machine until it breaks and then repair it.  Imagine how many more seconds it would take for that pit crew if they had to figure out who was doing what, go and get the gasoline, check to see if the tires were inflated, locate the jack, etcetera. 

Risk Mitigation for Machine Failure from Breakdown

• Establish a preventive maintenance program based on data.  Some data sources could be wear level, cycle time, or timing.  On your personal vehicle there are wear bars on the tires to indicate when the tread is low and the tires need replacing.  Oil changes on your car are needed every 3 months or 3,000 miles.  Air and fuel filters need to be changed at a higher level of miles dependent on your vehicle.  Having a race car pit crew mindset will reduce both the unplanned downtime and the planned as well.

Unknown Causes of Lowered Production, Worn Parts, or Break Downs

Some companies do not know why the machine stopped running or is running slower.  In every company there is a need for an RCA (Root Cause Analysis) capability.  This would be a person, or better yet people, that can methodically look at a break down and find the root cause for the failure.  Through DMAIC methodology, companies can find those failures as part of regular maintenance and provide solutions to prevent that failure from ever happening again.

Risk Mitigation for Unknown Causes of Equipment Failure

• Create certified problem solvers versed in BDA (Break Down Analysis) tools as well as DMAIC (A3s and such).

Connect with Performance Solutions by Milliken to Mitigate Risks of Machine Failure

At Performance Solutions by Milliken, we have experienced manufacturing consulting personnel to help mitigate any of the risks identified above.  Our Practitioners have hours and hours of real-world experience helping companies, just like yours, across different manufacturing industries, implement solutions to reduce equipment failure.  Learn more about our manufacturing consulting services or contact us for an initial discussion.