Equipment failure analysis

What does equipment failure analysis involve? It is primarily a systematic, methodical investigation of the causes of machine damage. Using the right methods, it is possible not only to repair current faults, but also to obtain information that will enable the introduction of lasting preventive measures. In practice, the analysis is based on tools such as cause-and-effect diagrams and fault tree analysis, which allow you to identify non-obvious, root causes of problems – instead of just “treating” the symptoms.

According to ISA, the average manufacturing plant loses 5-20% of its productivity as a result of downtime. Equipment is the cause of up to 80% of this downtime, generating significant financial and operational losses. Implementing analysis can significantly reduce downtime, while investing in prevention is an effective way to reduce maintenance costs. Examples include the implementation of equipment condition monitoring in a semiconductor company, which resulted in a 15% increase in productivity and a reduction in downtime by almost a third. In the long term, reliable failure analysis promotes increased reliability, improves work safety, and increases the company’s competitiveness.