Erratic failures

In our search to discover the root causes of failure, we discussed the first three elements of failure in the previous chapter. We are now going to turn our attention to the next batch of three reasons in terms of ‘why does equipment fail?’

Why Does Equipment Fail?

• Intermittent Errors
• Accidents
• Wear and Tear

Intermittent Errors

The most difficult problem to diagnose is intermittent, sometimes referred to as an erratic failure which is almost impossible to predict. In my earlier years in the IT industry as a programmer, an intermittent problem was the one we always tried to run away from. Mainly because the problem was sometimes so difficult to re-create and if you cannot re-create a problem then how do you know if you have ever resolved it?

Intermittent equipment failures occur randomly and under various operating conditions. Many times these types of failures are caused by sudden overloads on electrical or hydraulic systems, especially with today’s computerized components that seem to lock up and baffle even their designers. Finding a solution to an intermittent failure is not easy. Most of the time the problem cannot be isolated through re-creation and requires a component-by-component replacement approach until the right one is identified and the problem disappears. This is not necessarily a practical approach, however sometimes trial and elimination is the only solution to fixing this type of equipment breakdown.

Accidents

A piece of machinery being handled or operated in an incorrect manner can lead to internal parts becoming damaged and causing failure. Equipment being dropped can also cause components such as gearboxes and clutches to become dislodged or damaged, which would also cause the machinery to cease working properly.

A work-related illness or injury can not only put an employee out of work for a while and impact their quality of life but it may also damage your business’s productivity, finances, and reputation all of which can be difficult to recover from. Accidents can also lead to issues with Health and Safety regulations.

Health and Safety Health Disregard

Equipment operators need to take seriously their duty to recognize and avoid accidents. Pushing back legally required cleaning schedules or missing one routine maintenance inspection for equipment might not seem that important at the time but it can have serious consequences. A poor health and safety culture will cost your reputation, as failure to recognize the importance of this culture can result in business productivity loss and an increase in staff turnover as morale falls.

Everyone should feel safe at work and if not they may decide to look elsewhere for employment. We need to:

• Respect health and safety responsibilities
• Keep our staff motivated
• Retain good productive employees
• Work free of harm

Wear and Tear

There are three areas to discuss under the heading of wear and tear as depicted in the following image”

Obsolescence

Obsolescence can be described as machinery, equipment, furniture, apparatus, tools or implements, or other similar property that may be defective or may have become worn out or obsolete or no longer used or useful in the operations of the borrower or its subsidiaries.

Organizations use technology to increase productivity, drive profitability and remain competitive and employees are attracted to organizations that use current technology equipped with tools for work efficiency, communications, and the ability to work remotely.

Out-of-date machinery, software, and operating systems are a security risk due to: 

• Cyber-attacks and data security breaches
• Environmental impact
• Less energy efficient
• More resources needed
• Larger carbon footprint
• Customer service improvement
• Communications ability
• Negatively impact business reputation

Surface Degradation

Surface degradation is by far the main cause of machine unavailability and it is also a reason for increased vibration. Vibration increase and excessive component heating are signs that something is going in the wrong direction.

In the case of non-typical vibrations, the main causes are:

• Defective bearings and gears
• Electrical and mechanical failures in motors
• Problems caused by misalignments, due to imbalances or unstable bases, bent shafts, pulley or belt failures, mechanical gaps, aerodynamic or hydraulic problems

Besides from non-typical vibration and heating, other failure indication sources are:

• Water and oil leaks
• Corroded pipes
• Smells
• Abnormal sounds

Corrosion

Corrosion of vital industrial parts, such as couplings and gearboxes, is one of the most common causes of equipment failure. Corrosion of components can be especially problematic when the machinery is exposed to water contamination. As well as creating rust to form on the interior and exterior of the machine, water increases the speed at which oil oxidizes, which ultimately leads to the part operating within an acidic environment.

Why Does Equipment Fail?

Intermittent Errors

Accidents

Wear and Tear

These three types of failure cover quite a wide spectrum of issues. The intermittent or erratic failures may give us quite a run around to isolate and resolve but the remaining two error types can be controlled by simple health and safety education and regular visual inspections.

Once again we are reminded that we do not have to live with failure. We can deal with the destructive force of failure in our organization and bring it under control for the benefit of everyone concerned.

Let’s now move on to the final batch of three failures.

For more information email us at info@strobe-al.co.za or visit www.strobe-al.co.za