Causes of

Equipment
Failure !
By-Beletew Nigat
Causes of Equipment Failure

Discussion points
 Improper maintenance
 Electrical disruptions
 Operator error & Untrained operators
 Wear and tear
 Poor culture
 Ignoring warnings
 Improper operation
 Overloading
 Failure to read the owner manual
 Reactive maintenance
 Major Causes of Drainage blockage
 Benefits of preventive maintenance
Causes of Equipment Failure (Cont.)
Improper maintenance
Bad (or no) reliability culture
Applying a band-aid solution on it
and say, “I’ll figure this out when
things calm down”. A band-aid
solution becomes a semi-
permanent solution until it stops
working and becomes a full-
fledged failure. This kind of fix
can lead to personal injury, a
major accident, or damage.
Causes of Equipment Failure (Cont.)

Electrical Disruptions
Electrical problems such as short circuits, power
fluctuations, or faulty connections can disrupt the
functioning of machines and System malfunctions
result from internal failures within equipment, such
as electrical or mechanical faults, software bugs,
or control system problems.
Causes of Equipment Failure (Cont.)

Operator error (or human

error) is broadly defined as the
cause of an unintended consequence
due to a bad decision, distraction,
voluntary deviation from the
procedure and so on
Causes of Equipment Failure (Cont.)

Failure to read the owner manual

Why people don t read user manual?

Most users believed that it was unclear to find

information as the structure and layout made it
difficult to use and navigate.

There are 5 types of manuals

1, User Manual. User manuals are intended for both
professional and inexperienced equipment users, ...
2, Training Manual. Individuals use training manuals to
prepare for a procedure or skill, ...
3, Operators Manual. ...
4, Service Manual. ...
5, Special-Purpose Manual.
Causes of Equipment Failure (Cont.)

wear and tear is one of the most

common causes of equipment failure and quite
frankly, it is inevitable regardless of the type
of equipment. Even Physical Wear and Tear.
This cause of industrial machine failure
includes things like bearing failure, metal
fatigue, corrosion, misalignment
Causes of Equipment Failure (Cont.)

Poor culture
The fourth most common cause of equipment
failure is bad (or no) reliability culture.
In certain organizations, management might
have a warped definition of Reliability Culture
Failings If operators are pushed as hard as the
equipment and production goals are so tight
that they feel like they can't take a minute
poor reliability: any system is often considered
reliable as a result of rapid repair in order not
to delay production times too much.
Causes of Equipment Failure (Cont.)
Ignoring warning signals.
Warning lights on screens are there for a
reason, often signaling issues that need
to be addressed,
Ignoring warning signals ... The
experienced operator manages to identify
potential risks in the machine
Causes of Equipment Failure (Cont.)

improper operation " is

a correct and usable phrase in written English.
You can use it when referring to an action or
method that is done improperly or incorrect.
Example: The machine's improper operation
caused a malfunction.
This is when failure can be attributed to human
errors caused by machine operators. · Wrong
amount of Preventive Maintenance:
Causes of Equipment Failure (Cont.)

1,The cold room door is not closed

tightly
2. The frost on the unit cooler or
exhaust pipe is too thick
3. Low compressor efficiency
4. Improper adjustment of the
expansion valve or ice blockage
Causes of Equipment Failure (Cont.)
Do not lean on the elevator door be
careful when you enter and exit
the door.
WEDGING ITEMS INTO DOOR FRAMES

ITEMS BLOCKING DOORS FROM

CLOSING

TROLLEYS OR PRAMS INTERFERING

WITH CLOSING DOORS

Repeated ramming of trolleys and

prams in between lift doors to prevent
them from closing might cause the
door-sensor devices —which are
installed along the edges of the door —
to malfunction over time.
Causes of Equipment Failure (Cont.)

Overloading. Exceeding a
machine's designed capacity can stress its
components excessively, leading to
premature failure.
Causes of Equipment Failure (Cont.)
The problem caused by
commercial laundry machine
washing less load
Generally no but a small load can
sometimes get unbalanced. One
towel that's absorbs water with
other clothes that don't absorb
as much water can lead to uneven
distribution of weight. The
machine might not be able to spin
properly or even get unbalanced
enough to cause damage.
Causes of Equipment Failure (Cont.)
There are several common reasons why equipment
failure can happen.

The major ones are listed below:

Improper operation (Misuse of equipment)

 Misuse of equipment’s is a number one cause for

equipment failure.

 Never allow an operator to use equipment they are not

qualified to run.
Causes of Equipment Failure (Cont.)
Major Causes of
Drainage blockage
Cooking oil
Cooking oil and fat
shouldn't be poured down
sinks as it can cause
blockages. If you do not
have access to a food
waste recycling service,
put it in a sealed
container and place in the
general waste bin.
Our oil consumption ?
Causes of Equipment Failure (Cont.)
Major Causes of
Drainage blockage
Grease
A grease is a white residue that usually forms
around your pan after frying bacon or any
food. When you pour grease down the drains,
it sticks around the inner lining of your pipes.
Over time, grease would block the passage of
your drain system.

What You Can Do to Prevent Blocked Drains

due to Grease:

Do not pour grease into the drains. Dispose of

them properly.
Flush hot water down the drains if you
accidentally spill grease.
Causes of Equipment Failure (Cont.)

Toiletries

Many plumbers would tell you that baby

wipes, tampons, condoms, sanitary pads,
and tissue paper should not ever go
down the drain. Rightfully so, because a
blockage would be certain in the very
near future. Those little toilet
deodorizers that sit on the side of your
toilet covers are also a major
contributor to a blocked toilet. It is
easy to knock them off from the side
of the bowl. Once flushed down, these
can easily get stuck in the pipe works.
Causes of Equipment Failure (Cont.)

Hair
An average person loses 60-100
hair strands a day. It is no
wonder why they always end up
blocking bathroom drains and sinks!
Hair can also come from your furry
pets whenever you bathe them in
the tub. Strands of hair accumulate
and tangle together, which would
eventually create massive clumps in
your pipes. The worst experience
that our plumbers had was pulling
several meters of hairs from a
customer’s drainage system, which
already solidified together with a
mix of grease, grime, and dirt.
Causes of Equipment Failure (Cont.)
Too much preventive
maintenance

Every time you get into a

machine to maintain it, you open

up that piece of equipment to

a whole set of risks, and over

time those risks can compound

and lead to machine failure.

Causes of Equipment Failure (Cont.)
Benefits of preventive maintenance
improves equipment
improved safety less downtime efficiency

increase productivity minimizing risks budget constraints

efficiency extend asset lifetime

cost savings
Causes of Equipment Failure (Cont.)
Failure to perform preventive
maintenance
Tracking equipment and machinery
with asset tags can help to keep
maintenance schedules on track and
equipment operating at maximum
operational efficiency.

Preventive maintenance results

in:

 Up to a 30% reduction in
energy and maintenance
costs
 35% to 45% fewer
breakdowns on machinery
 Reductions in downtime by up
to 75%
Thank you