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10 Most Common Causes of Machinery Failure


Machinery parts and gearboxes suppliers like YB Components often help customers mend broken machinery with replacement parts as well as advice on proper usage and maintenance. It places them in a unique position to understand the many different problems that affect industrial machinery.

Calling upon many years of experience dealing with all manner of problems that affect industrial equipment, here is a list of the top ten issues that cause machinery failure, and how to prevent them.

1. Poor Maintenance

It is crucial that you put in place a regular maintenance schedule that ensures all lubrication points are checked daily, all variable speed belts are monitored for wear and tear and that the likes of rollers and chains have not accrued any damage which can in turn damage other parts of the equipment.

2. Not Following the Manufacturer’s Instructions

The manuals that come with equipment should contain a wealth of information about how to conduct proper maintenance and calibrate machinery correctly. Many such manuals will also have a troubleshooting section that shows you how to deal with common issues.

3. Overworking Equipment

Constantly running machines at maximum performance can reduce the lifespan of various components. To ensure a longer life, operate machinery a little under its maximum performance level most of the time to avoid premature wear and tear.

4. Bad Electrical Connections

More and machinery is electronically controlled these days which brings a new issue to contend with in the form of poor electrical connections. One of the main causes of this problem is the simple gathering of dust and dirt around the connectors, which can be easily cleaned away with compressed air.

5. Untrained Users

If the machinery operator hasn’t been fully trained in how to get the optimal performance out of a machine, then their subsequent poor handling will often lead to unnecessary failure and downtime. Gearboxes suppliers often hear of poor handling being the reason for machinery failure.

6. Incorrect Storage

Storing equipment is as vital as operating it correctly. The manufacturers should provide recommendations on proper storage, so ensure that all equipment is stored exactly as it was intended to be.

7. Harsh Conditions

A lot of machinery is built to be operated specifically in harsh conditions, but there is also a lot of equipment that will succumb to the elements quickly if used in environments they have not been designed for. Make sure your machinery can handle whatever conditions it needs to be operated in.

8. Ignored Warning Signs

Many machines include warning signals that indicate there is a problem somewhere, and it can be easy to ignore these if the equipment is still seemingly operating at optimal efficiency. However, this is the perfect moment to identify a problem and get it fixed before failure occurs.

9. Misaligned Tighteners

Rollers, chains and variable speed belts feature tighteners that must remain aligned correctly. If they are misaligned then they will add unnecessary tension to the belt which in turn creates more wear and tear.

10. Operating Machinery with Worn Parts

When a machinery component wears out and needs replacing, you should check all the other parts that worked in conjunction with that part. Wear on one component can cause wear on another, so always ensure every component is in good working order.

If you require any replacement components such as rollers or variable speed belts to get your equipment up and running again, then contact YB Components who are the UK’s leading machinery parts and gearboxes suppliers.