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October 2005 |  |
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"An Alien Space Ship Landing On The Factory Floor"
As equipment becomes more complex, human behavior can play a big role in unexpected breakdowns. Technology has advanced so far and so fast that it threatens to outpace the ability of many people to understand the equipment they use. Workers can be intimidated and overwhelmed. One observer even likened the arrival of a new production machine to "an alien space ship landing on the factory floor."
HARD TO UNDERSTAND
At the same time, budget cuts are squeezing funds to train employees in the proper operation and maintenance of equipment. They can't always tell when something is going wrong. Even when they do, they may be uncertain and wait too long to act. The result can be an equipment breakdown that interrupts or shuts down operations. Sometimes our clients learn this lesson the hard way:
LOSSES CAN BE COSTLY
- A medical center had a power outage. Several hours later, an MRI machine made an unusual noise when it was turned on. Instead of turning it off, the flustered operator called the service company. A technician told him to shut down the MRI, but it was too late. Condensation on the magnet and connections had shorted out the sensitive machine. Total paid loss: $635,499.
- A plastics manufacturer won a contract to make a quarter-million lids and finish assembling cups for sale in gas stations. It was a new operation for the shop and the operator of the injection molding press placed the unfamiliar die in backwards. That stripped the teeth off the machine's gear, broke the shaft and destroyed the bearings. Total paid loss: $30,098.
- During a test in an ethanol plant, the relief valve to an emission scrubber was closed and a half hour later a fermentation tank split. The owner speculated that excessive carbon dioxide pressure had built up. He wasn't sure. The equipment was the latest technology, and it was the first time they tried the required test. Total paid loss: $29,788.
