Manufacturing industry

How to manage with equipment breakdowns within a factory

For those who are responsible for managing the manufacturing operation having a major breakdown will end the stress levels flying. Did you know there are actually some hidden opportunities to be made out of equipment breakdowns?
You can gain insights into the causes of failure by improving the overall setup of the equipment and the future downtime. Clear and simple documentation of the event means that things like a service report can be done to provide the workers with blueprints for how to solve any future breakdown incidents and improvement programs.

Here are some ways to deal with equipment breakdowns:

Pinpoint the cause of the problem to fix the underlying problems

Equipment and machines can break down for any type of reason from wrong parts, flawed equipment, inconsistent maintenance, poor operation and incorrect setup and installation. In the case of an industrial air compressor break down, it is important first to screw tach it from the unit it is fixed to, in order to make sure there are no blockages or seep through. And then the next step would be to examine why the break down occurred. Specialists and technically experienced people are required to do the job as an amateur would end up making the situation worse or hurting himself.

Maintenance technicians can perform a check, but this will not address the main cause. A workaround will get the production back in order without too much delay, so when it comes to an isolated incident it doesn’t see as a big contributor to the downtime. Small problems that are frequently occurring are often the worst contributors to lost production time. To resolve the issue, find the cause and work out how to prevent it.

Doing a comprehensive service report will be able to pinpoint and explain the malfunction to help you understand why the breakdown did occur and how you can use the information to ensure it doesn’t happen again.

Working on machine

Know how the fault was fixed so you can equip yourself in future

Having detailed documentation in the event of a failure can help to fix the problem if it happens again in the future. This is brief that can be looked up shall the problem occur with a report and step by step instructions on how the problem can be fixed. You need a service technician to resolve the problem and to give you a service report. This report will include the contact details for the safety protocols and the steps that need to be taken to fix the problem.

Ensure you have made staff aware of the issue

If the equipment is faulty or not working correctly this can be a danger. Ensure that you make all the staff aware that the equipment is not working correctly, unplug it and put a sign on it stating it is not working correctly. Ensure the supervisor keeps an eye on the equipment to ensure nobody decides to start using the equipment which can lead to injuries.


Ensure that an inspection is carried out of the broken or faulty equipment via someone who is qualified to do so. All equipment must be checked regularly to ensure it meets the safety standards and that it is working order and safe to use. Especially in the case of water chillers, ensure they are renovated regularly and checked internally for any flaws or breakages for optimal performance.


When equipment has broken down ensure that everyone is trained on how to make repairs if it is safe for them to do so. Even if a machine is replaced ensure everyone is trained how to use the equipment properly to prevent injuries and malfunctions from occurring.

Each workplace will have a different set of rules and regulations for how they deal with equipment breakdowns. Ensure you are familiar with the rules and regulations shall you come across faulty or broken equipment.