How to Handle Machine-Down Situations

As a business owner/maintenance supervisor, you realize that you lose production time and revenue every minute your machine is down. System failures can cost you thousands of dollars. To avoid costly downtime, it is imperative to quickly get your operation up and running with the most sensible and cost-effective solution. What do you do when several options exist to get your system back online? Should you bring it back to working order by simply repairing its failed components, or will upgrading yield the most benefits in the long term? There are several things to consider determining the best solution: repair, refurb, retrofit, reverse engineer, or replace.

First, let’s go over your options.

1. Repair

Repairing existing equipment is a quick and straightforward option. Repairing means fixing what is in disrepair to bring it to the same state the machine/system was in before it broke. Items are replaced if broken beyond repair but not upgraded. After a repair, the machine/system should work exactly as it did before it broke – no better, no worse. Performing simple repairs on your machine/system is often an inexpensive and practical option to get you back in business. You can rely on the CDWdrives repair department to quickly determine the reasons for component failure and provide a detailed repair quote and job

5. Replace

Replacing a system/machine is when you disconnect it from your operations and replace it with a completely new one. A newly built machine/system can be very beneficial. It is often more productive and runs more efficiently with less energy consumption and noise. A machine with newer components will have better performance and durability (with proper maintenance, of course). An added benefit is that more recent devices will meet today’s safety standards. Think it will take forever to get a new system built? That’s not always the case! We have experienced engineers on staff to help you through the design process and will assist in selecting the right components.

Here are some essential questions to consider before determining your best option – Repair, Refurb, Retrofit, Reverse Engineer, or Replace.

1. What’s your timeline?

Ideally, you would want to consider machine refurbs and upgrades during scheduled machine maintenance periods, allowing ample time to implement the best and most cost-efficient course of action. But if you’re in a dire breakdown situation where you need the machine running again ASAP, you might be limited in options. We can quickly determine the reasons for your equipment failure by testing, disassembling, and inspecting all components for wear, breakage, and damage. Because we are a distributor for many high-quality parts manufacturers, we can get the required replacement parts quickly.

If you often find yourself in the same machine-down situation, consider retrofitting predictive-maintenance technologies into your system. It may cost a little extra at first, but it will be worth it in the long run, so you’re not stuck in the same pickle next time (and losing revenue from unplanned downtime).

2. How was your system performing before any breaks?

Was your system performing just fine, or do you need increased speed, precision, or other performance gains? If your machine has been running great, a simple repair may be all that’s required. But if your machine’s performance has been poor, you might consider refurbishing, retrofitting, or replacing the unit to get it up to snuff with your production needs.

3. Is your system overconsuming energy?

Older machines/systems can be energy hogs. If you’re tired of paying steep energy bills, consider an upgrade with either retrofitting or replacing the system, as modernized machinery is more energy efficient.

4. Can you hear me? How loud is your machine?

If your machine is unbearably loud, upgrading equipment often reduces noise. Retrofitting your device with new components or upgrading to newer technologies can result in considerable noise reduction.

Tips for using your maintenance time wisely!

If you can plan your downtime, you have the opportunity to make improvements.

Get proactive instead of reactive.

Predictive maintenance technologies are more accessible and affordable than ever! Components that monitor system performance can be installed on almost any machine, allowing maintenance to know when something’s wrong before it breaks. (No crystal ball needed!) Systems can also be outfitted with automated equipment to perform machine lubrication and other routine or preventative maintenance tasks. Compared to simply repairing a part, the long-term saving rewards often outweigh the initial cost of upgrading components and technologies.

Buy some spare parts while you’re at it!

When your machine is down, you don’t want to waste time scrambling to your purchasers to source components ASAP. In worst-case scenarios, the part you need isn’t in stock, and any wait can be excruciating when you’re watching production dollars go down the drain. So, think ahead and have spare parts available to allow your maintenance team or repair facility to respond quickly to your service needs.

Is your machine compliant with safety standards? Now’s the time to check!

While waiting for a machine to get back into service, you can take advantage of the time to ensure it’s up to code with applicable machine safety standards. You may want to consider an inspection and upgrade any out-of-date machine safety devices.

Summary

System failures cost thousands of dollars in downtime per day. The choice is yours to do a simple repair, but consider the longer-term benefits of refurbishing, retrofitting, or even replacing older and out-of-date machines with one that will save you money in the long run. And always remember, you have a partner in CDWdrives to help with any option you choose.