Five Industrial Measures to Improve the Quality and Reliability of Equipment

Reliability of Equipment

In the last few decades, there has been a rise in the popularity of quality management systems. Many companies are looking for ways of reducing their product defects while at the same time maximizing of quality of their products. To make this happen, various initiatives and business processes have been instituted. Some of these processes include TQM and Six Sigma. It is generally agreed that variations in equipment performance and processes accounts for a majority of the defects that are witnessed today. Some of these defects could have a profound effect on the way in which the customer perceives the end product and the company as a whole.

The focus of this article is on the measures that can be taken to improve the reliability of the instruments and equipments that we use so that the margins of error and product defects can be reduced.

Scholars have put forward that process accuracies can be improved if the instruments used to measure the constituents are reliable, well calibrated and functional. Equipment reliability is critical in ensuring that the components and subsystems are functioning well without failing at least for a commendable period of time. Theory has it that errors can be introduced to equipment at five main stages in its lifecycle. These five phases are Design phase, Purchase phase, Store phase, Installation phase and lastly the maintenance phase. Based on this phased approach to curb equipment error and defects, you must know how to control these six stages.

 Maintaining Equipment Quality and Reliability

Unless the root causes leading to equipment failure are addressed, it will be very difficult to enhance equipment reliability. The following discussion addresses some of the causes of equipment failure and also includes accompanying measures to rectify problems..

Proper Application and Equipment Use

Many equipment failures originate from misuse. Essentially misuse means that the equipment is used in a manner that is outside its functional performance parameters. By design, most equipment is made to function within specific operating environments. When equipment is misused or misapplied, it will not be accurate, secondly it will not produce the intended results, and lastly its operational function will be compromised. Reasons for misapplication are many but one of them is wrong procurement practices.There are instances where a limited amount of equipment is purchased but is expected to perform for a far greater range of functions. To rectify this and boost operations, policies should be instituted covering the range of equipment that is needed to complete work efficiently..

Operating Practices

Equipment operators that do not follow the right procedure will easily get the wrong results. Equipment can function well only when the right procedures and practices are applied. Either due to lack of training or resources or both, improperly used equipment will produce erroneous and defective products. This lowers their reliability and quality. To help counter this, there should be operating manuals that need to be put in place in addition to training such that the operators will be fully aware of the way in which they need to operate the equipment to yield accurate and reliable results.

Equipment Maintenance

Equipment needs to be maintained regularly. It the equipment is faulty due to long usage without proper maintenance regimes then the kind of results produced will also be faulty. Maintenance may include practices such as equipment calibration where the equipment is marked as balanced in order to capture the right data during measurements. In case the equipment in question has many parts, some of these parts may also be replaced so as to enhance its overall performance.

Age of Equipment

This is also a factor that you need to bear in mind. After long-term usage, wear and tear  is inevitable. This can result in errors when using the equipment. To manage this, you need to replace equipment with new ones.

Management Systems

Equipment reliability and the quality they give is to a great extent affected by the skills of the operators and the management system that is in place. If the system discourages employee involvement in operational standards for instance or if there is no hazard identification and elimination system that is up and running, these conditions can affect equipment reliability and longetivity. Ensure that the management system that is in place recognizes the need for minimum equipment operating standards. This will have a multiple positive effects for quality output.

Author bio:

Mr. Moore is a management systems expert. He deals with all facets of management systems including employee operations and their ability to manage equipment opertaion. He occasionally writes for sites such as http://zenithinstruments.com.au.