Zero Equipment Failure | As I have been visiting different production areas, I have often seen that the production areas fail from all sides just because of equipment failure. As it becomes difficult to survive in the market, the quality of the product is not what it seems, etc. And it is natural that equipment stoppage is expensive, reduced productivity is common, and there are also safety risks. All these inefficiencies affect product quality and product cost.
On the other hand, there are many manufacturing sectors that want to improve their qualifications, such as achieving zero equipment failure. Which is actually almost an impossible feat to fully achieve. But it should always be noted that the goal of “zero equipment failure” will get you awfully close to zero failure, which would be commendable.
List actions to achieve zero equipment failure:
- Perform regular maintenance.
- Monitor the performance of the equipment.
- Providing necessary training to employees.
- Implement a preventive maintenance program.
- Use high-quality replacement parts.
- Keep a record of detailed maintenance information.
- Develop a culture of maintenance.
- Adopt modern technology.
- Monitor external factors.
- Conduct regular audits.
So how should the goal of zero equipment failure be approached, and what steps can be taken to get as close to zero failure as possible?
Perform regular maintenance.
As I believe, it is not a difficult task to follow the steps to achieve zero equipment failure, it is just a matter of changing a few daily habits and proactively taking the necessary steps.
If we monitor the equipment regularly, we can avoid the problem that sometimes the equipment stops suddenly. Nothing actually “suddenly” happens, but we “Turn a blind eye” to disturbances in internal processes. So, the maintenance department / operator does not treat the equipment at the right time.
That is why regular maintenance is important to keep equipment running smoothly and reduce the risk of unexpected breakdowns. In fact, each equipment has a different routine maintenance procedure, method, and timing requirement, which can be easily ascertained from the equipment manufacturer.
Now what about maintenance? So, maintenance generally includes regular inspection of all components, lubrication of moving parts and replacement of worn or damaged parts. As mentioned earlier, the frequency of maintenance will vary depending on the type of equipment, the environment in which it operates and how often it is used.
Monitor the performance of the equipment.
As we regularly maintain the equipment, it is also necessary to regularly monitor the equipment. Based on monitoring the performance of the equipment we can easily identify potential problems, if the problem is small, it can be eliminated before it becomes bigger.
Keep in mind that there are a few important points to keep in mind when inspecting equipment. If something abnormal is found during the inspection, such as the temperature of the equipment is higher than required, there is excessive vibration, there is more noise than normal, or there is a different performance than usual, it indicates a possible failure, which should be noted immediately. .
Currently, no inspectors even need to directly inspect the equipment. We can deploy the system, using it the potential problems can be easily detected using advanced monitoring systems. It is also worth noting that such systems can also detect common deviations, thereby helping to quickly identify problems and take corrective action before equipment failure occurs.
Providing necessary training to employees.
If an equipment operator, employee, or supervisor has insufficient understanding of the necessary operating procedures, monitoring or use of the equipment, it is itself a severe problem.
Every employee should be trained in the necessary information before using the equipment, or after upgrading the facilities. Properly trained personnel may be able to identify potential problems early. At the same time, employees need to be fully informed about the proper operation of the equipment and any safety procedures that need to be followed.
I believe that not only management training should be provided, but employees should also be trained in how to regularly maintain and monitor the performance of the equipment.
Implement a preventive maintenance program.
This is a necessary procedure, which reduces the chances of equipment failure. It is better to deal with any incident before it happens rather than waiting for it to happen. It is said that “it is better to build a pond before it breaks”. Preventive maintenance is also something like that.
A preventive maintenance program is a systematic approach to equipment maintenance designed to prevent equipment failure. The program includes regular inspections, lubrication, cleaning, and replacement of worn or damaged parts. The program should be tailored and implemented to the specific needs of each piece of equipment based on its age, usage and operating environment.
It is said, “Don’t sit down to dig a well when you are thirsty” It is obvious that how to solve such problems before they occur, or preventive maintenance should be done. Thus, the plans for each preventive maintenance are determined based on the type of equipment, the manufacturer’s requirements, and other factors. But implementing simple preventive maintenance procedures can still prove effective.
Use high-quality replacement parts.
If you really want to extend the life of your equipment, we have high-quality replacement parts should be used. Which is more dependable and durable? We must also understand that if inferior parts are used, it becomes difficult to tell when they will completely wear out or break, resulting in unexpected equipment shutdowns. In the end the problems will increase instead of decreasing.
Keep a record of detailed maintenance information.
One thing to keep in mind is that whenever a maintenance procedure is carried out, it should be recorded. Keeping a record of every type of maintenance, and the work done during the maintenance procedures. Each and every job should be described in detail. Through this type of information, if any information needs arise in the future, it can be obtained. Also, based on this information, the manager can check if any failure has occurred, as well as understand its trend and pattern and make future plans.
In fact, maintenance teams can use this type of information to plan future maintenance and schedule downtime for repairs. And if any changes or upgrades are made to the equipment, the information should also be recorded on it.
Develop a culture of maintenance.
In the above point we have seen that we should create and implement maintenance programs, use high-quality replacement parts, etc. procedures, but one thing is very important to understand when these two points are needed? The answer is, if there are defects in the maintenance procedures. So the most important thing is that if the maintenance process itself is developed as a culture, there will be a significant reduction in equipment failure.
Maintenance of equipment in any manufacturing sector is an important aspect of business success, so developing a culture of maintenance is essential.
Adopt modern technology.
When there are innumerable equipment in the production areas and the manpower is limited, it is very important to have a special innovative technology that can monitor the process, performance and other possible problems of the equipment.
In the present modern era, the adoption of new technologies for monitoring is very fast, as such systems are working very successfully in manufacturing sectors. Which is really cool.
Advances in technology have made it easier than ever to monitor equipment performance and spot potential problems before they become major problems.
There are many tools available today that can assist in the maintenance and monitoring of equipment. Including remote monitoring systems, predictive maintenance software, and maintenance management software.
Look, trusting and spending on technology can be a really tough task, but the benefits should also be seen. When the number of problems decreases, then the invested amount will get return in the long term. Note that it is important to evaluate the cost-benefit of each technology investment. Select solutions that provide the most significant return on investment.
Monitor external factors.
Be especially aware that it is not necessarily only internal factors in the production area that cause equipment failure, external factors may also be present. Equipment failure can sometimes be caused by external factors. Such as changes in temperature, humidity or vibration levels that are not favourable to the equipment, which can cause failure.
It is important to monitor these external factors. And adjust maintenance programs as necessary to ensure that the equipment remains in optimal condition.
For example, if the equipment is operating in a high humidity environment, additional maintenance may be required to prevent rust or corrosion.
Likewise, if the equipment is operating in a high-vibration environment. It may be necessary to install vibration dampeners to reduce wear on moving parts.
Conduct regular audits.
Audit is a very broad concept, but here we will look at it in terms of tools. Any production area can arrange audits for its equipment as per its requirements.
Regular audits can help identify any weaknesses in the tool maintenance program, and make necessary improvements. Audits may include inspections of equipment, reviews of maintenance records, and communications with personnel.
The audit team can use the results of the audit to improve training programs. Modify maintenance schedules, and resolve any problems that contribute to equipment failure.
Achieving zero equipment failure is a challenging goal. But by following these steps, it is possible to minimize the risk of equipment failure and achieve maximum uptime.
Conclusion
It is not an easy task to achieve zero equipment failure. But, if possible, with a proper approach.
With a combination of preventive maintenance, ongoing monitoring and regular audits, you can reduce the risk of equipment failure.
If processes are systematically designed, and implemented as needed, they can save time and cost.
Equipment failure can be costly not only in terms of repairs and replacements. But also in terms of lost productivity, wasted materials and missed opportunities. By focusing on maintenance, you can minimize these risks. And ensure that your equipment stays in top condition for as long as possible.