The Hidden Costs of Machine Misalignment
Machine misalignment is a commonly underestimated problem, frequently dismissed as a minor inconvenience. However, the true cost of this issue extends far beyond initial perceptions, particularly when factoring in today's supply chain challenges. The ramifications of misalignment can quickly escalate into a substantial expense due to downtime, equipment damages, overtime for repairs, and disruptions to the supply chain.
So, what is the actual financial impact of a misaligned machine, and why does it matter?
Quantifying the cost is a straightforward process involving an understanding of the machine's production value, downtime expenses, and repair costs. Grasping these elements allows for a comprehensive evaluation of misalignment costs over time and underscores the rationale for investing in predictive maintenance.
When assessing the cost of misalignment, consider the following questions:
How much revenue does the machine generate?
What is the anticipated duration of machine downtime?
What is the financial toll of the machine's downtime?
Are repairs necessary, and if so, what is the associated cost?
How long will the repair process take?
What are the labor costs associated with repairs, including repair time and downtime?
To calculate the cost of misalignment, sum up the downtime cost, labor expenses, and estimated repair costs, including associated labor. Factor in lost revenue during the downtime and the anticipated energy cost related to misalignment. Studies, such as those conducted by Acoem USA and various engineering schools, suggest that misaligned rotating equipment can increase energy costs by 3-5%, while realignment can reduce energy costs by a similar percentage.
Downtime + Cost of Repairs + Cost of Labor + Lost Revenue + Energy Cost = Cost of Misalignment
Considering the current state of the supply chain is crucial. Delays in sourcing replacement parts or disruptions to the supply chain can significantly amplify the overall cost of a misaligned machine.
Understanding the potential expenses associated with misaligned machines prompts the question: How can these costs be mitigated?
The solution lies in developing and implementing a predictive maintenance strategy. Investing in an effective strategy ensures the prolonged efficiency and profitability of machines. Equip your team with the knowledge and tools necessary to execute the strategy efficiently. Commit to the proactive monitoring and repair of machines to prevent issues before they escalate.
If you have inquiries about developing a predictive maintenance strategy for your plant, reach out to us for guidance and support!