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Machine breakdowns are frequent in industrial and manufacturing environments, significantly impacting productivity, profitability, and business operations. Machine failure refers to the unexpected stoppage of a machine or equipment, leading to production downtime and delays in delivering products or services. It impacts productivity and efficiency in manufacturing industries. Irregular or insufficient maintenance leads to wear and tear of machine components, causing lubrication issues and the accumulation of dirt or debris. Furthermore, mechanical or electrical malfunctions in motors, bearings, or sensors can trigger sudden breakdowns. Improper usage, overloading, or negligence by operators contribute to stress, wear, or damage to machine parts, leading to failures. Environmental factors also play a significant role in accelerating machine degradation and breakdowns. Proper preventive measures are crucial for minimizing downtime and ensuring the smooth operation of machinery.

Machine Breakdown

Man

•   Training
  •    Insufficient training
  •    Lacks operation/maintenance skills
•   Human error
  •    Failure to follow procedures
  •    Improper handling
  •    Incorrect settings

  Machine

•   Poor design/ manufacturing defects in construction
•   Mechanical failure
•   Electrical failure

Material

•   Inferior quality
  •    Degradation/ component failure

Method

•   Overloading
•   Incorrect operating procedures
•   Ignoring warning signs
•   Infrequent lubrication
•   Neglecting preventive maintenance schedules

Measurement

•   Failure to track KPIs
•   Inadequate monitoring of performance
•   Insufficient monitoring of fluid level/ temperature/ vibration

Environment

•   Presence of dust/ corrosive substance
•   Extreme temperature/ humidity

Fishbone analysis, also known as Ishikawa or cause-and-effect analysis, is a method used to identify and understand the root causes of a problem or issue. In the context of machine breakdowns in industrial and manufacturing environments, Fishbone analysis helps to uncover various factors contributing to failures. Factors such as irregular maintenance, mechanical or electrical malfunctions, improper usage, environmental influences, and insufficient preventive measures can be systematically analyzed using the Fishbone diagram. By organizing and examining these causes, organizations can develop effective strategies to minimize downtime, enhance productivity, and ensure the smooth operation of machinery.

Who should use the Machine Breakdown template?

• This template is a knowledge booster for anyone who is interested to know the potential reasons for machine breakdown. We welcome everyone to explore our template repository. Your collaboration will give us exposure to some unique thoughts and views.

Why use this template?

• This template lists the crucial factors that are responsible for machine breakdown.
• It helps to make the root cause analysis process simple and easy to comprehend.
• Craft your template or reuse this with some modification for cause analysis of other problems in ProSolvr by smartQED.

Curated from community experience and public sources:

• https://fiixsoftware.com/blog/5-causes-of-equipment-failure-and-what-you-can-do-to-prevent-it/
• https://www.farmprogress.com/farming-equipment/10-biggest-causes-of-machinery-breakdowns-and-how-to-prevent-them-