Unreliability of equipment and machinery

Nature

Reliability in equipment depends upon the quality of the initial research, its design, the quality of the materials used, the quality of the parts used in its construction, the external influences upon its operation, and the frequency and quality of maintenance. The continuing increase in the complexity of mechanical and electromechanical systems increases the probability of equipment failure.

Incidence

Unreliability of equipment and machinery is a pervasive issue across various industries, leading to significant economic losses. For instance, a study by the International Society of Automation estimates that unplanned downtime due to equipment failure can cost manufacturers between $50,000 to $1 million per hour, depending on the industry. In sectors like mining, construction, and manufacturing, equipment failure rates can exceed 20%, highlighting the critical need for reliable machinery to maintain productivity and safety.
In 2018, a major incident occurred at the Tanjung Priok Port in Jakarta, Indonesia, where a malfunctioning crane led to a significant disruption in cargo handling operations. The crane's failure resulted in delays for over 200 shipping containers, causing an estimated loss of $1.5 million in operational costs and affecting supply chain logistics for several businesses reliant on timely deliveries.

Claim

Quality control is uneven among the industrialized nations with some countries lagging well behind. In addition, there is an inadequate use of both the automatic, computerized safety features in installations, and the systems reliability measurements of machinery or equipment configurations.

The reliability of machinery is inversely proportional to the number and significance of any persons watching it.

Counter-claim

Equipment and machinery are more reliable than their human operators. Industrial accident figures indicate this. The continuing increase in the complexity of industrial systems increases the probability of human failure.