The motor that drives the exit conveyor on a process machine failed. This type of failure used to result in 4 hr of downtime. Factors in that 4-hr figure include operator reporting, maintenance response, expediting purchase of the replacement, and collecting the necessary tools. Now this failure takes only 2 hr to resolve.
However, maintenance should not congratulate itself just yet. Responding to delays in a failure because it happens enough that the delays get noticed is only a partial solution. Two other parts are:
- Identify and extend the principles to other repairs. Rather than have a special operator reporting system for this one issue, develop a speedier operator reporting system for all repairs. Rather than create a special equipment locker just for this one line, examine each piece of critical equipment to see if that solution is appropriate.
- Determine why this failure keeps occurring. Was there a process change or equipment modification that changed what type of motor is needed? For example, the Class A motor in the original design was adequate for the temperatures encountered but now with modifications a Class B is needed. Simply replacing the motor with a repeat spec means a repeat failure.
About the Author
Mark Lamendola
Mark is an expert in maintenance management, having racked up an impressive track record during his time working in the field. He also has extensive knowledge of, and practical expertise with, the National Electrical Code (NEC). Through his consulting business, he provides articles and training materials on electrical topics, specializing in making difficult subjects easy to understand and focusing on the practical aspects of electrical work.
Prior to starting his own business, Mark served as the Technical Editor on EC&M for six years, worked three years in nuclear maintenance, six years as a contract project engineer/project manager, three years as a systems engineer, and three years in plant maintenance management.
Mark earned an AAS degree from Rock Valley College, a BSEET from Columbia Pacific University, and an MBA from Lake Erie College. He’s also completed several related certifications over the years and even was formerly licensed as a Master Electrician. He is a Senior Member of the IEEE and past Chairman of the Kansas City Chapters of both the IEEE and the IEEE Computer Society. Mark also served as the program director for, a board member of, and webmaster of, the Midwest Chapter of the 7x24 Exchange. He has also held memberships with the following organizations: NETA, NFPA, International Association of Webmasters, and Institute of Certified Professional Managers.