December 17, 2021
Does your business rely on the extensive use of heavy machinery and equipment? If that is the case, then you are certainly familiar with the trepidation of downtimes and short-lived machinery. Undeniably, downtimes, equipment failures, and unanticipated production halts cost more than mere idle labor time.
The actual cost of downtime is more severe than what meets the eye. According to a recent survey that surveyed 72 multinational industrial and manufacturing organizations, large plants lose about 323 hours annually due to downtime. Resultantly, firms endure a devastating cost of about $532,000 per hour. Heartbreakingly, the cost surpasses $172 million per plant each year.
The cumulative global figures are scarier than these.
If you dig deeper into the problem, you will realize that the biggest culprits are not human errors or machine mismanagement. Instead, lack of maintenance and the use of improper oil filtration systems amongst others.
Apparently, these hidden culprits lead to shorter machine lifespans which lead to the replacement of a particular part, or the whole machine. The latter should be the last thing you want on your table after the aforementioned costs.
Surprisingly, you can easily avoid these costs if you adhere to the tips that follow.
However, it is noteworthy that these tips are not only applicable to the manufacturing industry but are also relevant to mining, farming, aerospace, shipbuilding, locomotive manufacture, and much more.
So let’s raise the curtains:
Adequate labor training and education should form the base of your onboarding processes. If an employee is not fully equipped with the knowledge on how to operate a particular machine, he/she will make mistakes. These mistakes may ultimately lead to the machine breaking down or its complete demise.
Resultantly, it is crucial to thoroughly educate and train both new and existing employees about proper equipment maintenance, management, and operation. Regular workshops and seminars should do the job.
Oil filtration largely affects a machine’s operation capacity. For proper equipment functioning, the oil used must be devoid of any contaminants. However, the latter necessitates the use of high-quality filter carts and oil filtration systems.
On the other hand, using oil filtration systems of a sub-standard quality may reduce the efficiency and service life of your machinery and equipment.
Another factor that depletes machinery is friction between its moving parts. The constant rubbing creates heat that ultimately leads to increased wear and tear. Contrarily, adequate lubrication effectively combats the issue and increases the lifespan and functionality of the machine. Hence, it is vital that you keep your lubricant levels in check at all times.
However, focus on the word ‘adequate’. You should not bathe the parts in a lubricant as this may lead to soot and unnecessary grease build-up. The best way forward is to refer to the machine manual for proper instructions.
This is perhaps the most neglected part of machinery operations. Undoubtedly, laziness finds its way even in the most professional atmospheres. But reread the statistics above to get your facts straight . Do you think it is worth it?
Mind you, crying over spilt milk will get you nowhere in the end. And $172 million is a lot more than what you can afford to spill.
Resultantly, it is important to regularly clean the vents, filters, cooling fans, and seals to avoid any clogging due to soot or dust.
Seasoned machine operators know all to well the importance of periodic machinery inspection and maintenance. In fact, the two are just as important as cleanups (if not more). Just like your body needs periodic doctor visits, your machinery also requires regular checkups to detect any issues before they become detrimental.
For example, if a cooling fan is not working properly, and the responsible person does not carry out any inspections, the issue will persist unnoticed until another fatal issue results from it. Ultimately, the latter will lead the way to unnecessary repair costs which could have been avoided in the first place.
On the same note, delaying the replacement of parts that have reached the end of their useful life will also result in similar issues.
Hence, prevention is better than a cure, and as a wise businessperson, one should invest more in prevention rather than detection and correction. Remember, a stitch in time saves nine.
In a world where industrial needs evolve at breakneck speed each day, Harvard Filtration stays abreast with top-notch technology and high-end customer service. No matter the type of industry you operate in, we have the perfect exquisite oil filtration systems and filter carts to keep your machinery free of contaminants. Contact us to know more.