What is an equipment breakdown?

What is Equipment Breakdown Types of Breakdowns Examples

→ Equipment breakdown refers to any machine, part, or system failure or malfunction.

→ That results in a stoppage of production or service and an impact on the business.

→ Equipment breakdown can include manufacturing equipment, electrical systems and sub-systems, heating and cooling systems, computers, telecommunications infrastructure, etc.

Table of Contents:

Reasons for Machine Breakdowns & Impact on Business:

→ Refer to the below-mentioned most common reasons for breakdowns:

  • Wear and tear,
  • Mechanical failure,
  • Electrical issues,
  • Operator error,
  • Environmental factors like weather temperature changes, etc.

→ Equipment breakdown can impact operations and lead to downtime.

→ Downtime converts into a loss of productivity, which leads to financial loss.

→ When equipment breaks down, it is necessary to find the root cause of the problem so we can prevent it in the future.

→ Now we will learn about the Five Different Types of Machine Breakdowns.

→ Also, You can visit 7 Types of Abnormalities Presentation.

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Five Types of Equipment Breakdowns

→ Five types of Equipment Breakdowns are mentioned below.

  1. Forced Deterioration
  2. Natural Deterioration
  3. Weak Point Part
  4. Out of Operating Condition
  5. Lack of Knowledge

→ Now we will discuss all the causes in detail.

Five Types of Equipment Breakdowns

1. Forced Deterioration:

→ Forced deterioration refers to the accelerated decline in equipment or material performance or condition due to external factors.

→ In other words, we can say that Forced Deterioration is the reduction in the functionality of machines due to improper usage by operators.

→ Let us take one example to understand this concept:

→ Assume a car that is constantly used in overload conditions and never changes oil.

→ That is an example of Forced deterioration and it causes parts to wear out at a much faster rate.

⏩ The most common causes of Forced Deterioration are mentioned below.

  • Lack of Cleaning (accumulation of Dirt & Dust)
  • Lack of Inspection (e.g. loose nuts, bolts, etc)
  • Lack of Lubrication
  • Lack of Re-tightening
  • Improper use
  • Overloading

→ The impact of forced deterioration leads to a reduction in functionality, efficiency, and lifespan of the equipment.

⏩ How to prevent the Forced Deterioration?

→ Refer to the below-mentioned countermeasures to prevent Forced_Deterioration:

  • Following proper operating procedures
  • Implementing preventive maintenance plans (cleaning, lubrication, inspection)
  • Avoiding overloading
  • Implement the visual control for better understanding by all team members.
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2. Natural Deterioration:

→ Natural deterioration refers to the gradual degradation in the condition, quality, or functionality of equipment or machines due to normal wear and tear.

→ There are not any external damaging factors or forces involved.

→ Every Mechanical Part has a limited lifespan, therefore even under basic conditions, natural_deterioration will occur.

→ Let us take one example to understand this concept:

→ Assume a car that is constantly used in normal conditions.

→ Over a period of time the tires, clutch, and brake pads wear out due to normal wear.

→ That is an example of Normal deterioration.

⏩ The most common causes of Normal Deterioration are mentioned below:

  • Friction and contact between parts
  • Environmental Factors
  • Mechanical Wear and Tear
  • Material Fatigue
  • Chemical Reactions
  • Aging of Components

⏩ How to prevent the Natural Deterioration?

→ Refer to the below-mentioned countermeasures to prevent Natural_Deterioration:

  • Preventive Maintenance - Follow the Manufacturer's Recommendations, Develop a Customized Plan, and Keep Good Maintenance Records
  • Environmental Control - Temperature and Humidity, Dust and Debris, Vibration Control
  • Proper Operation - Train Operators, Follow Guidelines, Avoid Harsh Conditions
  • Storage Considerations - Cleaning and Preservation, Covering, Periodic Operation
  • Design for Durability - Material Selection, Modular Design, Accessibility for Maintenance

3. Weak Point Part:

→ The weak point of the part is basically a weak design part due to that part the breakdown happens.

→ In other words, we can say that the Breakdowns are caused by components that were not correctly designed to support their function.

⏩ The most common causes of the Weak Point Part are mentioned below.

  • Overload
  • Overheating
  • Corrosion
  • Accelerated wear

⏩ How to prevent the weak point part?

→ Refer to the below-mentioned countermeasures to prevent Weak Point Part:

  • Identify Weak Points and Implement Targeted Maintenance
  • Design Improvements of component
  • Spare Parts Management

4. Out of Operating Condition:

→ Equipment Out of Operating Condition means a machine or device that is unable to perform its intended function due to various reasons.

→ Due to out of operating condition, the machine might face different problems like malfunction, breakdown, or some other issue.

⏩ Different Operating Conditions of the Machine are mentioned below:

  • Temperature
  • Speed
  • Air Pressure
  • Hydraulic Pressure
  • Feed and Depth of Cut

⏩ How to prevent the out-of-operating condition?

→ Refer to the below-mentioned Countermeasures to Prevent Out-of-Operating Conditions:

  • One-Point Lessons and Operator Training
  • Visual Controls
  • Match Marks
  • Alarm Systems
  • Interlocks
  • Preventive Maintenance

5. Lack of Knowledge:

→ Sometimes Equipment fails due to a lack of knowledge of the operator.

→ There are more chances of machine failure if a nontrained operator is deployed on the machine.

→ Equipment competent operators are very important for preventing equipment breakdown due to lack of knowledge.

⏩ Different Examples of Lack of Knowledge:

  • How to handle breakdown
  • How to operate the Machine
  • How to Repair Machine
  • How to Install Mchine

⏩ How to prevent breakdowns due to a lack of knowledge?

→ Refer to the below-mentioned countermeasures to prevent breakdown with lack of knowledge:

  • One Point Lessons
  • Operator Training
  • Maintenance Standards
  • Work Instructions and SOP

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