Breakdowns in industrial machinery:
Types and causes

Breakdowns in industrial machinery are losses in costs, productivity and even the reputation of an industry. However, they are easier to avoid than they may first appear.

To achieve effective prevention, optimal maintenance and proper repair, it is essential to have a CMMS software software that prioritizes tasks, organizes and has an exhaustive control of the machinery.

Industrial machinery is one of the fundamental pillars of production in most companies worldwide. However, they face a serious problem that affects performance and efficiency affecting performance and efficiency: breakdowns in industrial machinery. These failures can occur for different reasons, such as lack of maintenance, wear and tear, problems with the power supply, among others.

It is important to know the different types of types of breakdowns in industrial machinery that can occur in a company in order to take preventive measures and minimize their consequences. The most common failures include electrical, mechanical, hydraulic and pneumatic problems. In this post we will explain in detail each of these problems, their causes and how they can be avoided or solved.

In addition, it is important to bear in mind that breakdowns can cause great economic losses to the company, since the production process is interrupted to the company, since the production process is interrupted, time and resources are lost and, in many cases, the damaged equipment must be repaired or replaced. For this reason, it is essential to to know the causes in order to minimize these breakdowns, plan the necessary preventive measures to avoid stopping the line and keep the industrial machinery in perfect condition. and keep industrial machinery in perfect working order.


Types of breakdowns in industrial machinery

Industrial machinery plays a fundamental role in the operations of factories and companies, so, like any other equipment, it can suffer frequent breakdowns.

Breakdowns in industrial machinery can result in significant economic losses, production delays and potential safety hazards for workers. Some of the most common types of industrial machinery breakdowns are described below:

  1. Mechanical breakdowns: These breakdowns are due to failures in machinery parts or components, such as. worn or broken parts, lubrication problems or misalignment of parts. or misalignment of parts. Signs of a mechanical breakdown may include unusual noises, vibrations, difficulty in moving the machinery or the presence of metal particles in the lubricating oil.
  2. Electrical faults: These breakdowns affect the electrical components of the machinery and can result from short circuits, overheating, connection problems or electronic component failures. Signs of an electrical fault may include lack of power to machinerylights and displays going out, or error messages on equipment.
  3. Hydraulic: These are due to problems in the hydraulic system that powers the machinery and may be the result of poor maintenance, use of inadequate parts or wear and tear of the parts.. Signs of hydraulic failure may include oil loss, low hydraulic pressure or fluid leaks.
  4. Pneumatic: These breakdowns are similar to hydraulic breakdowns, but occur in the pneumatic system of the machinery. They can be due to air leaks, blocked lines, damaged parts or valve problems. Signs of a pneumatic failure may include lack of air pressure, strange noises or loss of compressed air.

In conclusion, breakdowns in industrial machinery are an inevitable part of their use and can be caused by a variety of factors. It is essential to perform preventive maintenance and repair any problems immediately to minimize the impact on production and ensure the safety of workers. Find out how process digitalization can contribute to the monitoring of breakdowns.

Causes of machine failures

Industrial machines are a vital part of production in companies, factories and other manufacturing facilities. When a machine fails, it can negatively affect the entire production process and cause financial losses. Some of the main causes of industrial machine failures will be discussed here.

  • Lack of maintenance: One of the main causes of failure in industrial machines is lack of maintenance. Most machines require regular maintenance to function properly. If scheduled maintenance is ignored or improperly performed, machine parts can wear out or become damaged over time.
  • Overloading: Some machines are used too frequently or perform tasks that are beyond their load capacity. This overloading can cause sudden and unexpected stresses on machine components, which can result in mechanical failure.
  • Electrical failures: Industrial machines often require a large amount of electrical power to function properly. If there is a failure in the electrical supply or the machine's electrical system, it can cause damage to the machine's electrical and system components.
  • Use of damaged tools: some tools used in machines can also become worn or damaged with use, which can lead to premature wear and machine failure if used continuously.
  • Hydraulic system failures: Industrial machines may also have hydraulic systems for their operation. Failures in these systems may be due to leaks, blockages or hydraulic flow congestion, among other problems.

A preventive maintenance plan can be essential to reduce the likelihood of long-term failures. It is also important to use the right tool for each task and to have trained and knowledgeable personnel handling the machines for their proper use and care, as well as to be on the lookout for any signs of failure in industrial machines.

Software to prevent breakdowns in industrial machines

Specialized software can help prevent breakdowns in industrial machines in a number of ways, including continuous monitoring, data analysis, preventive maintenance, remote diagnostics and performance optimization, among others.

For this you can count on Mesbook's MES system for SMEs and large companies that optimizes maintenance tasks and reduces downtime is a great decision. It also allows the definition of preventive maintenance and action guidelines on each of the lines. It also guides the operator at all times and calculates stock, cost of materials, labor and more.

Marta Cejudo

Product Manager at MESbook

Marta Cejudo

Industrial organization engineer with 4 years of experience in real-time factory management as KAM.

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