Problem solved: Downtime caused by unexplained malfunctions

Unexplained malfunctions can sometimes bring your production process to a halt. They can often be resolved by simply restarting the machine, but after a few weeks, you find that the same problems are back. Sound familiar? UNIS Group has the solution!

Problems keep recurring, but the cause remains unknown? 

Our Field Service engineers see it every week: frustrated customers dealing with unexplained machine malfunctions. All the possible causes and solutions have been explored, but the problem persists. Where do these malfunctions stem from?

Common causes of unexplained malfunctions 

Frequently, the cause is disrupted communication between industrial modules. This can be due to time-sensitive components that are obsolete, as well as poor connections between modules caused by using the wrong tools, cabling or connectors, for example.

Machines may have been delivered by the manufacturer with the underlying cause of the fault already there. In addition, dust accumulation due to neglected maintenance, overheating, EMC disturbances, lack of knowledge, or incorrect configurations can also cause malfunctions. 

How can you prevent unexplained malfunctions?

Preventing these malfunctions starts with the installation of your machines and control boxes. One consideration is installing the correct communication cables, ensuring they are long enough and their resistance is not too high.

If proper standards and regulations are not followed during installation, it is highly likely that long-term problems will arise. Your machine could potentially run smoothly for 15 years despite having hidden problems that are not yet visible during the production process.

Ageing can often reveal these issues, along with all their consequences. In many cases, potential problems can be detected before they cause downtime with a comprehensive, independent inspection after the delivery and installation of your machine, as well as during production.

You can also prevent failures by preventively replacing time- and failure-sensitive components and by keeping control boxes clean and well-maintained. This reduces the risk of malfunctions and decreases downtime. 

Solution and risk analysis 

Repairing a malfunction can be a relatively simple job, such as replacing a cable. Unfortunately, this is rarely the case. If you are unable to find a solution, we can identify the potential risks and problems in your production and, where possible, solve them immediately. This allows you to avoid surprises and reduce risks that cause downtime.

Have you experienced unexplained malfunctions? Contact us and reduce downtime in your production. Problem Solved!