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Safe operations and handling of equipment for businesses

As a business, you understand the crucial role that equipment plays in industrial settings. You rely on these assets to streamline operations and enhance productivity.
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By Trisha Sirju , 

Vice President, Senior Risk Consultant, Marsh Advisory

05/10/2024 · 5 minute read

As a business, you understand the crucial role that equipment plays in industrial settings. You rely on these assets to streamline operations and enhance productivity. However, when unexpected equipment malfunctions occur, the consequences can be devastating. They can disrupt production processes, cause delays, and result in significant financial losses. Therefore, it is essential to prioritize the safe operations and handling of such equipment to ensure the well-being of employees, protect business continuity, and mitigate potential risks. Fortunately, by implementing best practices, such as employee training and proactive maintenance, businesses can quickly resolve equipment malfunctions and minimize their impact.

Five common types of equipment breakdown

To ensure the proper functioning of equipment and minimize disruptions, it is important to be aware of common forms of equipment malfunction. Factors such as environmental conditions, equipment usage, high vibration, and exposure to harsh chemicals can contribute to the severity of equipment failures.

Here are some of the most common types of equipment malfunction that every company should be aware of in order to address and resolve issues, improve equipment management, and enhance workplace safety:

  1. Electrical failure: Facilities with electrical equipment and heavy machinery are at risk of electrical failures, which can lead to electrocutions, fires, and machine damage. These malfunctions can occur due to problems with wiring, switches, circuit boards, or power supply issues.
  2. Mechanical failure: Unexpected malfunctions in the mechanical devices or systems of critical equipment can result in significant repair costs. These can include broken gears, bearings, shafts, worn-out motors, and misaligned components. Mechanical failures can be caused by wear and tear, improper use, manufacturing defects, corrosion, or fatigue.
  3. Thermal damage: Environmental changes can have a significant impact on certain assets and equipment. Exposure to extreme heat conditions can lead to equipment damage or breakdowns, while frigid temperatures can cause cold damage. Regular inspection and maintenance of equipment are crucial to reduce thermal damage and ensure proper functioning.
  4. Software or control system failure: Equipment that relies on software or control systems can experience malfunctions due to software bugs, programming errors, cyber attacks, or compatibility issues. These failures can disrupt operations and require technical expertise to resolve.
  5. Fluid system failure: Equipment that utilizes fluid systems, such as hydraulic or pneumatic systems, can experience failures due to leaks, blockages, or pressure issues. These malfunctions can affect the performance and reliability of the equipment.

By being aware of these common types of equipment malfunctions, companies are better able to take measures to prevent and address issues, ensuring smoother operations and minimizing downtime.

Risks associated with equipment failure

Equipment failure can pose serious challenges for your company, including:

  • Safety hazards: Inadequately maintained equipment increases the risk of workplace accidents and injuries. Malfunctioning equipment can expose employees to dangers such as electrocution, traumatic brain injuries, spinal cord injuries, crush injuries, and amputations.
  • Property damage: When equipment malfunctions, it can not only damage the equipment itself but also have a ripple effect on nearby assets or facilities, leading to additional property damage.
  • Unplanned downtime: Unexpected equipment malfunctions can result in unscheduled downtime, disrupting production processes and causing delays. This can lead to lost productivity and revenue losses.
  • Financial losses: Repairing or replacing malfunctioning equipment can result in unplanned and unbudgeted expenses, impacting your company's budget and profitability. These financial losses can be significant, especially if the equipment is critical to operations.
  • Reputation damage: Poorly functioning equipment can create unsafe conditions or environmental hazards, which can result in penalties or legal action for non-compliance with safety regulations or environmental standards. This can also harm your company's reputation and erode customer trust.

Best practices for equipment safe handling and longevity

To help mitigate the risks mentioned above, it is crucial to follow the best practices outlined below:

Adhere to manufacture instructions: Strict adherence to manufacturers’ instructions is vital in preventing machine breakdowns. Technicians and operators should thoroughly review and follow the instructions provided in the manuals. These instructions typically include calibration requirements, checklists, troubleshooting advice, and other important information for safe and efficient operation.

Provide ongoing training and education: Human error can contribute to machine breakdowns and safety issues. The team responsible for maintaining the equipment should have in-depth knowledge of machinery components, while staff should be trained on safe and successful utilization of any machinery they use. Regular training sessions should be conducted to keep employees informed about equipment upgrades or modifications. Continuing education will help prepare staff to be effective and efficient on equipment safety and handling.

Avoid overworking equipment: Every machine has its limits, and overworking equipment can lead to breakdowns, overheating, and reduced lifespan. It is important to ensure that workloads placed on machines are within their maximum capacity. If there is a need to achieve quotas or boost output, consider investing in new equipment rather than overworking existing machinery.

Create a comprehensive inspection checklist: A thorough inspection checklist is crucial to minimize unplanned downtime and frequent failures. Draft a checklist that covers all necessary inspections to help ensure immediate detection and resolution of potential issues. Include items such as equipment security features, electrical components and wiring, lubrication points, belt tensions, and an inventory of replacement components.

Conduct proactive maintenance: Adopting a proactive maintenance approach is more cost-effective than reactive maintenance. Proactive maintenance involves monitoring the environment and machinery conditions, allowing minor issues to be addressed before they become major concerns. A proactive strategy reduces the likelihood of unexpected failures and helps ensure smoother operations.

Safe operations and handling of heavy machinery and equipment are of paramount importance. Proactive measures can help ensure the well-being of employees, maintain operational efficiency, and safeguard the financial stability and reputation of the organization. By recognizing the importance of safe operations and handling, businesses can help create a secure and productive work environment while mitigating the potential consequences of equipment breakdowns.

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