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%(opens in a new tab) — 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 its 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 downside of routine maintenance is that it often requires equipment downtime. Mechanics may need to lock out machinery and systems to ensure safety during repairs. However, these short-term lockouts take far less time than a sudden malfunction or unplanned repair.
The company has control over when preventative maintenance happens. Mechanics can schedule routine shutdowns for times that have minimal 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 example, the average excavator lasts between 7,000 and 10,000 hours of use(opens in a new tab). Improper use, such as scooping at an unnatural angle or lifting objects beyond the machine’s weight capacity, can push this lifespan below 7,000 hours.
Companies can avoid this problem by training employees on the proper use of each piece of equipment they handle. Training should be part of onboarding for new employees and conducted as needed for existing staff, especially when new equipment is acquired. Regular refresher courses are also crucial for maintaining safety and maintenance protocols.
Prioritize safety inspections
Regular safety inspections can impact equipment longevity in two ways. First, inspections reveal issues of wear or problems that could affect performance if left unrepaired. Second, equipment must meet safety standards to remain operational. Regular inspections ensure compliance and help prevent the need for premature replacements.
Proper tools, such as lockout labels and lockout kits, are essential for minimizing disruptions during inspections and maintaining safety compliance.
Follow usage and storage best practices
Overload failures occur when machinery operates outside its intended limits. Equipment is designed for specific tasks, and exceeding its capabilities can strain components, cause fractures, or result in permanent damage. Manufacturers provide usage guidelines that employees should follow to prevent these issues.
Proper storage is equally important. Corrosion, humidity, and extreme temperatures can damage idle machinery and tools. Store equipment in appropriate environments and use clearly marked lockout cabinets to ensure safety and accessibility.
Regularly clean and check for wear
Cleaning is crucial for machine longevity. Dirt and debris can reduce lubricant effectiveness and cause premature wear on moving parts. Regular cleaning prevents these issues and allows operators to inspect components for signs of wear or fatigue. Although cleaning may require brief downtime, it helps avoid unplanned shutdowns and extends equipment lifespan.
Address issues promptly
Minor issues such as unusual noises or vibrations can indicate larger problems. Companies should establish policies requiring workers to report potential issues immediately. Early intervention can prevent small problems from escalating and reduce long-term wear.
Invest in technology and upgrades
Advancements in technology allow manufacturers to integrate new components and systems into existing equipment. For example, AI-powered systems(opens in a new tab) paired with sensors can detect performance anomalies and maintenance needs. These technologies can also help identify safety issues and support compliance.
Plan for emergency response
An emergency response plan protects workers and prevents equipment damage. Regular emergency response training ensures employees know how to react quickly and effectively in critical situations, safeguarding both people and machinery.
By maintaining equipment, training employees, and leveraging new technologies, companies can maximize equipment lifespan and reduce downtime.