Equipment Failure Causes, Risks, and How to Avoid Them with an Effective CMMS Solution

Manufacturing equipment is vital to production. When it fails, it can cost a company time and money. Equipment failures can cause businesses to suffer a number of negative consequences, including production downtime, financial losses, safety risks, and reputational damage. In some cases, equipment failures can even lead to catastrophic accidents.

Equipment Failure Causes, Risks, and How to Avoid Them with an Effective CMMS Solution

To avoid these negative outcomes, it is important for businesses to have an effective maintenance management system in place. A good maintenance management system will help businesses to identify potential risks, schedule preventive maintenance, and track the condition of their equipment.

One of the most effective ways to manage maintenance is to use a Computerized Maintenance Management System (CMMS). CMMS software provides businesses with a central database for storing information about their equipment, maintenance history, and maintenance plans. It also helps businesses to track and manage their maintenance backlogs, schedule preventive maintenance, and generate maintenance reports.

Equipment failures are common in organizations, especially those that rely heavily on machinery and equipment. In fact, it is estimated that equipment failures account for a loss of $50 billion per year in the United States alone. Equipment failure is defined as any unexpected malfunction or stoppage of equipment. It can lead to production delays, quality issues, and safety concerns.

There are many different types of equipment failures, but they can all be grouped into three categories: design failures, process failures, and human errors.

Design Failures: Design failures are the most common type of equipment failure. They occur when the equipment is not designed properly for the application.

Process Failures: Process failures are caused by poor maintenance or operating procedures. Wear and tear are the most common cause of equipment failures under processes. Over time, parts will inevitably start to wear down and break. This is especially true for parts that are constantly in use, such as motors and bearings. Improper maintenance is another common cause of equipment failures. If equipment is not properly maintained, it will likely break down prematurely. This can be due to a number of things, such as not replacing worn parts, not lubricating moving parts, or not cleaning equipment on a regular basis.

Human Errors: Human errors are the most difficult to avoid, but they can be reduced with proper training and procedures. If operators do not know how to properly use and maintain equipment, they can easily damage it. Operator error can also lead to safety hazards.

Risks of Equipment Failures

The risks of equipment failures are real and present in many industries. from transportation to healthcare, to manufacturing and beyond, the potential for a critical piece of equipment to fail can have far-reaching consequences.

Failures of equipment can have a number of negative effects on businesses, including production downtime, financial losses, safety risks, and reputational damage. In some cases, equipment failures can even lead to catastrophic accidents. Production downtime is one of the most common consequences of equipment failures.

When equipment breaks down, it can take a long time to repair or replace. This can cause businesses to lose a lot of money, as they are not able to produce products or services. Safety risks are another common consequence of equipment failures. If equipment is not properly maintained, it can pose a serious hazard to employees, customers, and the general public. Reputational damage is another risk that businesses face when equipment fails. If a business has a lot of equipment failures, it can damage its reputation and make it difficult to attract new customers.

How to avoid Equipment Failure

Equipment failures can be prevented with proper maintenance.

  • Corrective maintenance is used to fix equipment that has already failed.
  • Preventive Maintenance is used to prevent equipment from failing in the first place.
  • Condition-based maintenance is used to monitor equipment and perform maintenance only when it is needed.
  • Predictive Maintenance predicts when equipment will fail and schedules maintenance accordingly.
  • Routine maintenance is the most basic type of maintenance and should be performed on all equipment on a regular basis.
  • Avoiding maintenance backlogs as they are a common cause of equipment failures. They can be prevented by scheduling maintenance properly and maintaining accurate records.

How to avoid Equipment Failures with an Effective CMMS

One of the best ways to avoid equipment failures is to use an effective CMMS. As mentioned earlier, CMMS software provides businesses with a central database for storing information about their equipment, maintenance history, and maintenance plans. Another benefit of CMMS software is that it helps businesses to track and manage their maintenance backlogs. By tracking maintenance backlogs, businesses can ensure that all of their equipment is properly maintained. Finally, CMMS software can help businesses to schedule preventive maintenance. Preventive maintenance is a type of maintenance that is performed on equipment before it breaks down. By scheduling preventive maintenance, businesses can ensure that their equipment is always in good working condition.

In Conclusion

Equipment failures can cause businesses to suffer a number of negative consequences, including production downtime, financial losses, safety risks, and reputational damage. In some cases, equipment failures can even lead to catastrophic accidents. To avoid these negative outcomes, it is important for businesses to have an effective maintenance management system in place. A good maintenance management system will help businesses to identify potential risks, schedule preventive maintenance, and track the condition of their equipment. One of the most effective ways to manage maintenance is to use a computerized maintenance management system (CMMS).

CMMS software provides businesses with a central database for storing information about their equipment, maintenance history, and maintenance plans. It also helps businesses to track and manage their maintenance backlogs, schedule preventive maintenance, and generate maintenance reports.

If you are looking for a CMMS Software to help you manage your maintenance, then look no further! We offer a free trial of our software, so you can try it out and see how it can benefit your business.

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What Do Our Clients Says ?

Amrapali Exports - Esteemed Clients of cryotos
Anuraj Sharma - Maintenance Manager

The best thing about Cryotos CMMS software is that it always tells me when something needs to be fixed - before it breaks and cost me a fortune!

The software is very user-friendly, and even if I don't know how to do something, the support team is always there to help me out.

Most importantly, unlike other such software, Cryotos is editable and hence the user can modify how the software works as per their need, we made several changes in the workflow & flowchart with the help of development team.

I don't know what I would do without Cryotos! I've been using it for years, and it has saved me so much time and money. I highly recommend it to anyone who wants to manage their assets efficiently.

Resil Chemicals - Esteemed Clients of Cryotos
Jeevan Belliappa - Head, Information Technology

Since we've been using Cryotos CMMS Software, our asset maintenance management has been running more smoothly than ever. We're able to track and optimize our preventive maintenance with ease, thanks to the customized process workflow. This has been a lifesaver for our team!

The Cryotos CMMS software has allowed us to manage our assets more effectively and efficiently. It has helped us to improve our asset utilization. The software is user-friendly and easy to navigate, and the support team is always quick to help with any questions we have. We're very happy with the results we've seen so far and we're confident that we'll continue to see improvements in our asset management as we use the Cryotos CMMS software.

Planys - Cryotos Esteemed Client
Antony Jacob Ashish - Lead, R&D

Cryotos goes above and beyond when it comes to customer satisfaction. Planys Technologies use Cryotos for preventive/ corrective maintenance of our critical systems and not once did we face a problem that was not dealt with immediately. The team is extremely professional and helpful. We can rely on Cryotos when it comes to the operations and processes.

Thanks to the whole team for the amazing performance and thought leadership. It's rare to see teams that can put themselves in the customer's shoes and think from their perspectives - Cryotos team doesthat and more.

We recommend Cryotos if you are looking to put an end to your preventive maintenance problems and sign up with them!

Thanks to the team for an awesome job.

Xpert IFM - Esteemed Clients of Cryotos
Siva Shankar - AGM, (Operations & BD)

On behalf of Xpert FMS we would like to express our sincere appreciation for the excellent support Cryotos team have provided us for our building and facility management. Cryotos has always provided support that is timely and meets our expectations. Professionalism and quick response are the hallmarks of this team.

Sincere appreciation for the team's brilliant performance and wish them continued success. We highly recommend Cryotos as they have executed well on all assigned tasks and continue to outperform.

Thanks to all the hard work, our lives have become easier.

ST Jude India Childcare Centers - Cryotos Esteemed Client
Mukesh J - CIO

We are able to raised the workorder and tracking of these till the closure as helped us to provide better services our beneficiaries. Workflow-based work order management has helped us to define processes for each locations separatley. System provide notification once order is raised for assignment to engineer.

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