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Labels for Safety, Visuals and Facility ID Desktop Printers
Labels for Product, Wire and Lab ID Benchtop Printers
Ex: M210, 99048, SDPL-RED-38ST-KD6
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Safety and Facility ID Desktop Printers
Product, Wire and Lab ID Benchtop Printers
Barcode Scanners and RFID Readers
PaintStripe Floor Marking Stencils
Valve Lockouts & Hose Lockouts
Group Lock Boxes & Permit Control
- Confined Space Signs
- Construction Site Signs
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- Machine Operation Signs
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- Slip, Trip and Floor Obstacle Hazard Signs
- Blank Pipe Markers
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- Pipe Markers for Oil
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- Pipe Markers for Steam
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Pipe Marker Accessories & Mounting Brackets
Maintenance and Production Tags
Calculators and Assessment Tools
Product Finders and Data Sheets
- Confined Space Compliance
- NFPA 704 Diamond Guide
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- Proposition 65 FAQ
- What is OSHA Compliance?
- Top 10 OSHA Violations
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How to maximize the lifespan of your equipment
Every manufacturer has to contend with equipment downtime. A company will lose at least 5% of its productivity due to machinery malfunctions and repairs — and some firms lose as much as 20% — according to research by the nonprofit International Society of Automation (ISA). If not properly maintained, older equipment can cause a company to reach the higher end of the downtime spectrum.
The ISA also reports that many companies have trouble estimating their total downtime and that actual downtime is underreported in many cases. A business looking to avoid these types of errors, improve productivity and maximize return on investment should consider strategies for preventing unscheduled downtime and for generally extending the lifetime of your equipment.
Keep up with preventative maintenance
Scheduled preventative maintenance can keep machinery as close to peak performance as possible. While cleaning, lubricating and replacing worn components, technicians can assess the machine for signs of problems. In turn, they can spot issues and fix them before they cause a shutdown or irreparable damage to the equipment.
One negative aspect of routine maintenance is that it often requires equipment downtime. Mechanics may have to lockout machinery and systems to ensure safety during repairs, but these short-term lockouts take a lot less time than a sudden malfunction or unplanned repair would cost.
The company has control over when preventative maintenance happens. Mechanics can schedule routine shutdowns for times that have minimum impact on productivity.
Properly train employees
Some wear and tear is natural in a manufacturing or construction setting. However, improper use can increase wear and lead to damage that shortens equipment lifespan and necessitates additional maintenance.
For instance, the average excavator lasts between 7,000 and 10,000 hours of use. Improper use, such as scooping at an unnatural angle or lifting objects that are above the machine’s weight capacity, can push this lifespan under 7,000 hours.
Your company can avoid this problem by training employees on the proper use of each piece of equipment they use during their workday. This training should happen as part of the onboarding program for new employees, but should also happen as necessary for existing employees, particularly when new equipment is acquired. Even if employees are already familiar with operation of equipment, regular refresher training courses are important for keeping maintenance and safety protocols top of mind.
Prioritize safety inspections
Regular safety inspections can impact equipment longevity in two ways. First, inspections reveal issues of wear or other problems that could affect performance if not repaired. In industries like manufacturing with high safety standards, inspectors look for minor issues that could impact both safety and longevity. If your mechanics make immediate repairs, they can limit the impact of the problem.
Second, equipment needs to meet safety standards for your industry to remain in operation. Regular inspections can help you maintain the machinery so that it complies with safety standards and does not need to be replaced.
Using the proper equipment and procedures are very important for minimizing the disruptions of inspections. Make sure you have the proper lockout labels to denote shut-offs, and the right tools in your lockout kits to further support compliance. Additionally, mechanics should be equipped with all the proper tools they need to complete a job safely and effectively.
Follow usage and storage best practices
Overload failures occur when machinery gets used outside of its normal limits. Equipment is designed to perform certain tasks at a specific speed. If you use materials that fall outside of the machine’s capabilities in terms of weight or composition, it could strain movable components, loosen joints, cause fractures or bend the frame in a way that causes permanent damage.
Machine manufacturers will typically provide best practices for usage, and your employees should always work within defined limits when using the machine.
This care extends to times when the machine is not in use. Manufacturers will also offer guidelines for storage. Issues like corrosion, humidity or extreme temperatures can cause problems even if the machine is dormant, and the same goes for maintenance tools. Make sure you have proper storage environments for portable machinery and use clearly marked lockout cabinets or boards so that essential tools are stored safely and with convenient access.
Regularly clean and check for wear
Cleaning is an important aspect of machine longevity. Dirt, dust and debris can lower the effectiveness of lubricants, causing moving joints and ball bearings to grind and wear down prematurely. Dirty parts can also cause slippage, or the dirt itself can rub against parts, wearing them down.
Regular cleaning helps operators avoid these problems and offers the opportunity to inspect the components inside the machine for signs of fatigue or premature wearing. As with other longevity-focused processes, cleaning may require a temporary shutdown. However, it could help avoid longer, unplanned shutdowns and, ideally, save your company from replacement costs until the equipment reaches its maximum lifespan.
Address issues promptly
Minor issues may arise during operation. New noises, minor shaking or operations that take longer than usual can be signs of issues. Operators or observers will typically notice these problems during their workday, but they may not feel it’s necessary to report the problem right away, especially if the machine is otherwise operating normally.
Your company should have policies that require workers to report minor malfunctions or potential problems. You can identify the process for notification and name the manager or technician in charge of each machine.
Even if the equipment continues to operate, the issue could worsen or cause misalignment or wear that leads to larger problems in the future and shortens the machine’s lifespan.
Invest in technology and upgrades
New components, embedded systems and sensors are always in development as machine manufacturers seek to take advantage of the advances in these areas. In many cases, it may be possible to integrate new technologies into existing equipment. Though this process can be costly, you can measure the price against the cost of obtaining new machinery.
An example of these advances involves AI-powered systems. Paired with sensors, AI software can assess data constantly during machine operation and find anomalies and performance patterns that could signal an issue or the need for maintenance. In addition to early warnings about maintenance issues, AI can also detect safety issues and help the company maintain workplace protection compliance.
Plan for emergency response
An emergency response plan limits danger to workers and also saves machinery from damage. For instance, in a factory setting, the plan could call for immediately shutting down all equipment and sealing off separate areas when an emergency alert sounds.
While a plan is important, you should also provide workers with the opportunity to practice it. Emergency response training can improve safety and help everyone respond quickly to emergency situations to protect themselves, their peers and the equipment. Worker safety is paramount, and protecting equipment from irreparable damage during a disaster ensures it can remain in use.
With maintenance, proper operation and help from new technology, your company can maximize the lifespan of equipment while avoiding unplanned downtime and repairs.
