Unexpected machine failures can cost businesses thousands, or even millions, of dollars in lost production hours and emergency repairs. The good news is that there are ways to anticipate when your rotating equipment will fail and to be proactive, rather than reactive, in maintaining your equipment’s health.
We’re here to break down the true cost of machine failure and show you how you can reduce work stoppage costs and the cost of unplanned downtime in your facility.
What is Machine Failure?
Machine failure occurs when a piece of rotating equipment stops operating as intended. There are many possible machine failure causes, including abnormal vibrations, imbalance, misalignment or overheating.
The True Cost of Machine Failure
According to a 2022 Siemens study, the actual cost of machine failure is much higher than one might imagine.
Based on a survey of 72 leading multinational firms, the average downtime duration for large plants is 323 production hours per year, with the average cost of lost revenue being $532,000 per hour. That’s just over 40 business days of production and nearly $172 million in revenue lost due to work stoppages and downtime per plant per year.
Common Causes of Machine Failure
Common causes of machine failure include, but aren’t limited to:
- Abnormal or intense vibrations
- Misalignment
- Imbalance
- Overheating
- Wear and tear over time
There’s a way to address all of these issues before they lead to total machine failure: predictive maintenance.
How to Prevent Unexpected Downtime with Predictive Maintenance
When machines are run to failure, you’re left scrambling to arrange expensive emergency repairs during operating hours. With predictive maintenance, you can monitor your rotating equipment’s performance, spot potential warning signs and fix them before they result in the high cost of unplanned downtime.
At Cornerstone Mechanical, our ISO Category II-IV analysts specialize in vibration analysis and infrared thermography to provide every possible insight into the workings and health of your rotating equipment. By employing cutting-edge diagnostic technology, our team can look and listen for possible future failures in great detail.
Practical Ways to Reduce Unplanned Downtime
Several practical ways to prevent unplanned downtime include:
- Regularly scheduled inspections
- Condition monitoring services
- Regular laser alignment and dynamic balancing services
- Maintaining an inventory of spare parts
Don’t wait for your rotating equipment to break down—spot warning signs before you even get close to machine failure. At Cornerstone Mechanical, our team can work with you to schedule your predictive maintenance services at your convenience, giving you peace of mind that you won’t have to worry about navigating emergency shutdowns.
Call our team at (214) 225-7038 to schedule your predictive maintenance with Cornerstone Mechanical Services.