Five Causes of Equipment Breakdowns

When equipment breaks down it is necessary to find root cause of the problem. Let’s review five main causes.

Forced Deterioration

These breakdowns are caused by:

• Lack of Cleaning (accumulation of Dirt and Dust);
• Lack of Inspection (e.g. loose nuts, bolts, etc);
• Lack of Lubrication.

Lack of Basic Conditions (CIL) !

What will happen…

• if you never clean your stove?
• if you never check the air in your car’s tires?
• if you don’t change the oil in your car for 100,000 miles?

Example:

Forced Deterioration – Countermeasures

• Cleaning Standards – ensure parts are clean and SOCs are removed;
• Inspection & Visual Control – ensure nuts and bolts are in the right place;
• Lubrication Standards – ensure parts are well-oiled and running smoothly.

Natural Deterioration

These breakdowns are caused by:

• Friction and contact between parts;
• Friction between parts and the environment.

Every Mechanical Part has a limited life-span, therefore even under basic conditions (CIL) natural deterioration will occur.

What will happen…

• if you never change the brakes of your car?
• if you use the same shoe everyday for 2 years?
• after water flows in a pipe for 100 years?

Natural Deterioration – Countermeasures

• Time Based Maintenance (TBM)

Weak Point Part

Breakdowns caused by components that were not correctly designed to support their function. Component can suffer:

• Overload
• Over heating
• Corrosion
• Accelerated wear

It’s the same as:

• A chair breaking repeatedly, even if you keep replacing it;
• The brake in your car failing repeatedly despite maintenance.

Weak Point Part – Countermeasures

• Redesign component

Out of Operating Condition

These breakdowns are caused by:

• Equipment being ran out of specified conditions. Specified conditions might be:
  • Temperature
  • Speed
  • Air Pressure

What will happen if you…

• Plug your 110V hair dryer in a 220V receptacle
• Dry your cat in the microwave
• Drive an Indy Car in the city

Example:

Out of Operating Conditions – Countermeasures

• One Point Lessons
• Visual Controls
• Match Marks

Lack of Knowledge

• Breakdowns related to lack of knowledge of:
• Machine operation
• Machine repair
• Installation

It’s the same as:

• YOU driving a Nascar car during a race TODAY!
• You needing to pilot a jet flight

Lack of Knowledge – Countermeasures

• One Point Lessons
• Training
• Maintenance Standards