Machines are the heart of daily operations in industries and manufacturing units. A machinery breakdown can disrupt production and cause significant financial strain. Whether you run a small unit or a large manufacturing plant, understanding machinery breakdown is essential. This blog covers the basics of mechanical breakdown, its types, common causes and how to prevent them.
What is machinery breakdown?
Machinery breakdown refers to the sudden and accidental failure of machines or equipment, causing them to stop working. It could involve internal damage, broken parts, electrical faults or lubrication failures. These incidents can affect individual machines or entire production systems.
In many cases, equipment breakdown insurance covers these sudden failures, offering financial protection to businesses that rely heavily on machinery. These policies can help cover costs for:
- Repair or replacement of damaged machinery
- Business interruption losses
- Spoilage of raw materials or finished goods
It's important to note that typical property insurance policies may not cover internal machine failure, making this specific coverage particularly relevant.
Types of machinery breakdown
Let's walk through the most common types of mechanical breakdown situations you might encounter:
- Mechanical failure: This includes problems like broken gears, snapped belts, misalignment or damage to moving parts. These are often caused by fatigue, stress or overuse.
- Electrical breakdown: This type involves failures like short circuits, power surges, fuse failures or burned-out motors. Electrical issues are not only damaging but can also be dangerous.
- Lubrication failure: Machines that aren't properly lubricated can experience increased friction, overheating and ultimately breakdown. It may also lead to internal scoring and part-warping.
- Operator error: Not all breakdowns are due to faulty machines. In some cases, human mistakes like improper handling or lack of training can lead to major mechanical issues.
- Overload damage: When machines are pushed beyond their operational limits, components may break or wear out prematurely.
- Environmental damage: Excessive heat, moisture or dust can accelerate wear and cause failure. Contaminants in the air or nearby chemicals may also have corrosive effects.
- Vibration fatigue: Prolonged vibration, often due to imbalance or misalignment, can cause hairline fractures and eventually full part failure.
Causes of machinery breakdown
While it's helpful to know the types, understanding the causes of machinery breakdown can help you take preventive action. Below are the key culprits:
One of the biggest contributors is irregular or poor maintenance. Skipping scheduled maintenance checks or using low-quality spare parts can set machines up for failure. Ignoring oil change schedules, neglecting filter replacements or failing to check for part wear are common mistakes.
Older machines are more likely to break down. As they age, parts wear out and reliability drops. If your machinery is beyond its expected life cycle, a machinery breakdown is more likely. Many businesses delay upgrades, unaware of the cumulative costs due to frequent repairs.
Operators who aren't properly trained may misuse equipment or miss early signs of trouble, leading to equipment breakdown. Training helps avoid misuse and ensures machinery is handled according to its intended function.
Installing machines without following the correct procedures can result in poor alignment or unsafe conditions, increasing the risk of failure.
Voltage fluctuations, power surges or outages can damage electrical systems, leading to breakdowns. These are particularly risky for sensitive equipment such as CNC machines or robotics.
Consistent vibration from unbalanced parts or misalignments can lead to material fatigue and high friction levels (from lack of lubrication) can cause parts to seize or snap.
Excessive humidity, dust or corrosive environments can harm well-maintained machinery. Investing in proper insulation, dust control and air filtration can prevent unnecessary wear.
Modern machines often have embedded software for automation. Bugs, hacking or software failure can bring production to a standstill, especially in smart factories or IoT-enabled environments.
Conclusion
Machinery breakdown is an unavoidable risk in any industry that relies on machines or mechanical systems. While the reasons can vary—from mechanical breakdown to poor training—most of these are preventable with timely action.
Understanding the types and causes helps you plan better. Besides, securing the right group insurance offers benefits such as cashless treatment at network hospitals, preventive care and coverage for hospitalisation and surgeries.
Investing in policies like group health insurance is a smart move as it provides cost-effective coverage for employees, with premiums typically lower than individual policies because of the risk of being spread across a larger group. Employers often cover a larger portion of the premium, and the policy may extend to the employee's family members, including spouses and children.
Take the time to regularly review your machinery and train your staff. Prevention is always better than cure—especially when the cure involves halting production.
Disclaimer: The information provided in this blog is for educational and informational purposes only. It is advised to verify the currency and relevance of the data and information before taking any major steps. Please read the sales brochure / policy wordings carefully for detailed information about on risk factors, terms, conditions and exclusions. ICICI Lombard is not liable for any inaccuracies or consequences resulting from the use of this outdated information.