Equipment failure is expensive, time-consuming, and dangerous. So, let’s define it, learn the most prevalent causes of equipment breakdown, and find out how to prevent them.

What Is an Equipment Failure?

An equipment failure is a state where an asset doesn’t function as intended, resulting in unplanned downtime. For example, partial failures that maintenance teams can fix in minutes, as well as intermittent failures that seemingly occur at random. It also includes complete failures that may suspend operations for hours, days, or even weeks.

There are many different causes of machine failure, ranging from inadequate maintenance to improper usage. Whatever the cause, equipment failures can lead to expensive downtime and dangerous health and safety implications.

Without an effective maintenance strategy, most equipment will eventually fail. That’s why understanding equipment failure, including its various types and common causes, is vital.

The best way to understand and correct excessive failures is through data analysis — but that’s a difficult undertaking without the right software. A computerized maintenance management system (CMMS) can help maintenance managers prioritize maintenance activities, monitor equipment health, identify impending trouble, and prevent breakdowns.

8 Common Causes of Equipment Failure

Equipment reliability is key to success. That’s why it’s essential to know why equipment fails — so you can find the right solution. Here are 8 common causes of equipment failure:

1. Incorrect Installation

Installation issues include misalignment, poor tension, and failure to properly mount or secure components. Luckily, adequate machine operator training can prevent these issues. And for proper performance, safety, and to preserve your warranty, always follow the manufacturer’s installation guidelines.

2. Ineffective Equipment Maintenance

Proper maintenance is essential to prevent breakdowns. Mechanical equipment maintenance includes proper lubrication, routine parts replacement, and effective cleaning to keep parts free of dust and debris.

For maximum operational efficiency, teams need an effective preventive maintenance plan. This will help you avoid common equipment failures due to inadequate lubrication and premature wear and tear.

3. Excessive Preventive Maintenance

At the very least, over-maintenance wastes inventory. But it also puts additional strain on components, introduces environmental risks inside the machine, and distracts technicians from more pressing tasks. Instead of performing too much maintenance, take a balanced approach.

4. Aging Equipment

Without regular maintenance, older equipment is prone to failure. In fact, according to a report by Plant Engineering, aging equipment is the leading cause of unplanned equipment downtime. Maintenance managers can combat wear and tear by prioritizing ongoing maintenance, even on stable systems.

5. Environmental Factors

Poor storage conditions, such as pests, high humidity, or extreme temperatures, make it difficult to maintain asset health. Don’t compromise critical assets with inadequate facilities; make environmental audits part of your proactive maintenance strategy.

6. Overreliance on Reactive Maintenance

When maintenance professionals wait to perform repairs until equipment fails, it can indicate a poor reliability culture. You’ll see more instances of total equipment failure, along with increased downtime and higher repair costs. Make preventing equipment failure your goal — not reacting to it.

7. Insufficient Equipment Monitoring

You can prevent failure of critical equipment with effective condition monitoring. For example, you can detect excessive vibration with continuous vibration sensors. With the right condition monitoring tools and an effective CMMS, you’ll be able to detect and prevent potential failures before they occur.

8. Operator Error

Adequate operator training is essential to prevent errors. Equipment operators should have a clear understanding of all equipment components and safety procedures — this lets them recognize and avoid improper operation.

How Maintenance Teams Can Prevent Machine Failure: Best Practices

The right preventive maintenance strategies can help reduce equipment breakdowns. These are the key elements of an effective preventive maintenance program:

  • Routine Maintenance Schedule: Maintenance technicians must perform regular maintenance tasks (such as inspections and repairs) on a predetermined schedule. Use efficient planning methods and update, repair, and replace equipment as needed to reduce machine failure.
  • Condition Monitoring and Predictive Maintenance: Beyond regularly scheduled maintenance, which other maintenance tasks should you prioritize? Predictive maintenance helps you answer this question by identifying potential failures of critical components before they occur, reducing costly downtime.
  • Standard Operating Procedures (SOPs): Without SOPs, each technician may perform maintenance differently. This risks costly, dangerous errors that can cause breakdowns. Standardize your maintenance processes and train teams thoroughly to avoid inconsistencies.
  • Effective Training: Thorough operator training helps create a reliability culture that emphasizes prevention over emergency maintenance. It also helps teams spot warning signs of sudden failure and ensures proper operation, reducing breakdowns caused by operator error.
  • High-Quality Inventory: Purchase only reliable materials and parts. Whether original equipment manufacturer (OEM) or certified replacement parts, an upfront investment in quality can prevent costly maintenance issues and machinery failure in the future.
  • Data Tracking and Analysis: A comprehensive maintenance history log can help identify potential issues and enable data-driven decision-making for better results.

How do successful operations organize maintenance schedules, monitor performance, track inventory, and analyze data? With an efficient computerized maintenance management system (CMMS), like eMaint.