How to Handle Equipment Failure and Downtime Situations

4 min read

How to Handle Equipment Failure and Downtime Situations

Diann Sobolewski Sobolewski : Feb 6, 2023 3:43:52 PM

Replace parts and components Noise Reduction Purchase spare parts Refurbish Literature Reverse Engineer CDWdrives Service Department Energy Efficient Repair Retrofit
CDWdrives repair services

As a business owner/maintenance supervisor, you know you are losing production time and revenue every minute your machine is down. Significant 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?

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 damaged beyond repair but not upgraded. After a repair, the machine/system should work precisely 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 time estimate.

2. Refurbish

Think of refurbishment as a "facelift" for your machine/system. When we refurbish your older systems, they look and function like they did when they were new! Our technicians will inspect your equipment to determine if any components need replacement or repair and then thoroughly clean, fine-tune, re-lubricate, and perform necessary maintenance procedures to improve the machine components' performance.

3. Retrofit

When a machine goes through a retrofit, we install the new component(s) or feature(s) that were not initially available or designed into the original system. We can retrofit older machines/systems with newer tech to reap the benefits of cutting-edge advancements like io-link, predictive maintenance, remote connectivity, and more!

4. Reverse engineer

Reverse engineering may not be a commonly offered service by manufacturers, distributors, or service departments. However, it becomes a crucial solution when obsolete components fail, and the necessary replacement parts take time to come by. Instead of replacing entire systems, contact CDWdrives for expert reverse engineering services. After analyzing and reverse engineering the essential part(s), we will quickly get your equipment back up and running smoothly,

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). An added benefit is that more recent devices will meet today's safety standards. Do you 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.

Before determining your best option, here are some essential questions.

1. What's Your Timeline

Ideally, it would help if you considered 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 Preventative 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 its performance has been poor, you might consider refurbishing, retrofitting, or replacing the unit to suit your production needs.

3. Is your system overconsuming energy?

Older machines and systems can be energy hogs. If you’re tired of paying steep energy bills, consider upgrading by 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 considerably reduce noise.
 

 

Tips for using your maintenance time wisely!

If you can plan your downtime, you have the opportunity to make improvements. You can 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 let your maintenance team or repair facility 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 return to 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.
CDWdrives shop technician and engineer analyzing repair
CDWdrives repair services

Summary

System failures cost thousands of dollars in downtime per day. You can do a simple repair, but consider the longer-term benefits of refurbishing, retrofitting, or even replacing older and out-of-date machines with ones 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.