Material handling equipment (MHE) is essential for moving, storing, and controlling materials in manufacturing operations. However, MHE can also be a source of costly and disruptive downtime if not properly maintained and operated. In this article, you will learn about the most common causes of MHE downtime and how to prevent or minimize them.
One of the main causes of MHE downtime is human error. This can include mistakes such as loading or unloading materials incorrectly, misusing or abusing the equipment, or failing to follow safety procedures. Human error can also result from lack of training, communication, or supervision. To reduce human error, you should provide regular and adequate training for your MHE operators and handlers, enforce safety rules and standards, and monitor and evaluate their performance.
Material handling equipment downtime can be caused by mechanical failures, electrical malfunctions, operator errors, unexpected events like accidents or contamination, and inadequate system integration. These issues can disrupt manufacturing and logistical operations. To minimize downtime and optimize operational efficiency, a holistic approach combining regular maintenance, operator training, and robust technologies is needed. This includes addressing issues with conveyor belts, motors, gears, hydraulics, sensors, control systems, power supplies, and software glitches.
With technology changing in equipment mechanical failures are usually only due to not maintaining the equipment. Most down time nowadays is due to human error or abuse
Another common cause of MHE downtime is mechanical failure. This can include breakdowns or malfunctions of the equipment's components, such as motors, gears, belts, chains, or sensors. Mechanical failure can also result from wear and tear, corrosion, or contamination of the parts. To prevent or minimize mechanical failure, you should perform routine and preventive maintenance on your MHE, inspect and replace worn or damaged parts, and keep the equipment clean and lubricated.
Run to fail can be a huge mistake. Companies think they’re maximizing production time but more often than not…it causes longer downtime & more costly repairs
A third common cause of MHE downtime is electrical issues. This can include power outages, surges, or fluctuations that affect the equipment's operation or performance. Electrical issues can also result from faulty wiring, connections, or circuits, or from exposure to moisture, dust, or heat. To avoid or mitigate electrical issues, you should ensure that your MHE has a reliable and stable power supply, protect the equipment from environmental hazards, and check and repair any electrical problems as soon as possible.
A fourth common cause of MHE downtime is software glitches. This can include bugs, errors, or conflicts that affect the equipment's functionality or compatibility. Software glitches can also result from outdated, corrupted, or hacked software, or from improper installation or configuration. To eliminate or reduce software glitches, you should update and secure your MHE software regularly, test and troubleshoot any issues, and follow the manufacturer's instructions and recommendations.
A fifth common cause of MHE downtime is external factors. This can include factors that are beyond your control, such as weather, traffic, accidents, or emergencies. External factors can also include factors that are related to your suppliers, customers, or competitors, such as delays, shortages, or changes in demand. To cope with or overcome external factors, you should plan ahead and anticipate potential scenarios, have backup plans and alternatives, and communicate and coordinate with your stakeholders.
A sixth common cause of MHE downtime is continuous improvement. This may sound paradoxical, but sometimes you may need to stop or slow down your MHE to make improvements or changes that will enhance its efficiency or effectiveness. Continuous improvement can also involve testing, experimenting, or innovating with your MHE to optimize its performance or adapt to new challenges. To balance continuous improvement and MHE downtime, you should prioritize and schedule your improvement activities, measure and monitor their impact, and involve and inform your team and customers.
In my experience " The lack of Preventive Maintenance" and the attitudes that come with admins decisions to keep with the "Run it until it breaks misconception" not only leads to the cost of the break down but to the time the equitment is down . Set along with the worlds markets on availability of materials to make the repair .
I think a large part of this is lack of proper communication. So many deficiencies can be avoided through a proper means of communication.
In my experience and as pointed out earlier by Tammy, the idea of run to failure, it does not benefit in any way. In some situations it makes things worse by longer downtimes. Along with this idea is the idea of bandage repairs they do the same and even more damage at times. Continuous improvement needs to be just that improvement. A quick stoppage to do patch work is often included in the run to failure mentality. If the repairs are planned and performed correctly you will improve your process instead of possible contamination or under/overloading. Integrity needs to be emphasized not only from the ground worker and equipment operators but also all the way up the management chain.
Operator carelessness and disregard for the equipment causes needless damage and down time. Things break out in the field, but with a little care and consideration break downs can be decreased or avoided.
Lack of knowledge Before start the any job we need check the condition,last inspection report,proper calibration by authorised personal. For other matters we should go through the user manual or MSDS.