Machine Failure Causes & Prevention Strategies

Industrial machines are essential to normal daily operations. Unfortunately, they are not immune to breakdowns. Machine failure is a term that refers to the failure of a machine to perform its normal functions, leading to a partial or complete loss of utility. 

This article will shed light on some of the main reasons why machine failure occurs. We will also suggest actionable strategies to prevent machine failure, highlighting why using a Computerized Maintenance Management System (CMMS) like LLumin’s CMMS+ can help improve equipment performance and reliability. 

Common Causes of Machine Failure

These are some of the top leading causes of machine failure. Understanding how and why mechanical failure occurs can help you develop a maintenance strategy to prevent breakdowns and unexpected downtime. Consider how mechanical failures begin in the following areas:

Wear and Tear	Wear and tear are the most common causes that affect all machinery. Unfavorable operating conditions, misuse, improper storage, and neglect of regular maintenance are some of the factors that speed up this process. Unchecked deterioration can cause serious, occasionally irreversible damage.
Corrosion	Machine parts are susceptible to rusting from moisture exposure. Corrosion can cause chemical degradation within the machinery and weaken its structural integrity. For instance, combining certain oil additives and water can result in acidic conditions that exacerbate component damage.
Lack of Routine Maintenance	Budget constraints frequently lead organizations to rely on reactive maintenance strategies for complex or critical machinery. A lack of preventive maintenance frequently results in significant operational and financial losses due to emergency repairs and unplanned downtime.

Strategies to Help Prevent Machine Failure

There are several important strategies that you can use to deter machine failure. Implementing an advanced CMMS system, like LLumin’s CMMS+, is one of the most important ways you can help keep equipment up and running reliably for longer periods of time. 

We’ve listed the top strategies to prevent machine failure in an industrial environment below for further consideration. 

Root Cause Analysis

This approach involves a more in-depth look into the causes of a machine’s failure. Isolating and understanding the root cause is critical to developing an effective preventive maintenance strategy.

Preventive Maintenance

Failures can be avoided with frequent inspections, adherence to maintenance plans, and prompt component replacement. Preventive maintenance, like regular oil changes for cars, attempts to stop problems before they start by anticipating potential failure points.

CMMS Software

LLumin’s CMMS+ software can be critical in preventing machine failures and streamlining how your maintenance team identifies and mitigates developing issues: 

• Centralized Data Repository: LLumin’s cloud-based, mobile-ready platform acts as a centralized repository for all of your maintenance-related data, including maintenance history, SOPs, safety protocols, and asset management guidelines, making it easy for your entire team to access critical information throughout the day and with the convenience of a mobile device. 
• Automated Scheduling: LLumin’s automated system makes it easy to manage maintenance schedules, ensure the timely deployment of the appropriate technician to complete the task, and recommend the best maintenance task for the situation at hand. It also allows you to see and track all current and completed maintenance tasks, helping to ensure technicians complete assigned tasks and maintain high work standards. 
• Inventory Management: LLumin can completely streamline spare part inventory management, ensuring critical parts are available at the right time while reducing overstocking and stock-outs.
• Condition Monitoring: LLumin collects machine data in real time throughout the day using machine-level sensors. It will initiate automated maintenance tasks based on the actual condition of your equipment, allowing you to transition away from ineffective maintenance schedules that prevent you from improving your equipment’s health and performance.

Preventing Machine Failure With LLumin’s CMMS+

Machine failure is a well-known cause of unplanned downtime and financial loss. It is more common in organizations that rely on reactive maintenance strategies and can have disastrous snowball effects if not appropriately addressed. 

LLumin’s CMMS+ can help your organization break free from the run-to-failure cycle and lay the groundwork for a more proactive approach, resulting in increased machine uptime, improved performance, and more efficient maintenance operations.

If budget constraints prevent you from implementing proactive maintenance, consider how the LLumin can provide you with the tools and insights you need to optimize your maintenance operations and, ultimately, reduce long-term costs.