In machine design, durability and cutting-edge technology often steal the spotlight, but it’s the ability to maintain and service machines in the field that defines their success. For many engineers, designing for easy maintenance is one of the biggest challenges. A machine’s value and reliability aren’t just about how it performs when new but about how it and its components hold up down the line in real-world conditions.
In my little world, component failure seems to go in spurts. Last month I told you about two assemblies we had to replace: the door handle on my vehicle, which we were able to accomplish without calling in an expert, and the motor on our pool pump, which did require expert intervention.
More recently, the scroll compressor in our electric heat pump seized without warning. Despite extensive troubleshooting, the exact cause remains elusive, and getting timely service is proving to be surprisingly difficult. This experience is a stark reminder that no matter how innovative or robust the design, if a critical component fails and is difficult to service, the entire machine’s value suffers.
Similarly, that new motor/pump I mentioned earlier faced an issue not due to its core function but because its enclosure was warped; rainwater made its way inside and shorted the unit. This relatively small imperfection had outsized effects on operational reliability and maintenance needs. These situations shed light on the sometimes overlooked but importance of designing machines with serviceability at their core.
Your Feedback on Machine Design Challenges
Survey insights from last month’s blog confirm these challenges. When asked what aspect of machine design they find most difficult, an equal 31.25% pointed to selecting durable components and designing for easy maintenance—two sides of the same coin in machine longevity. Managing costs and integrating modern technology rounded out the biggest hurdles, cited by 6.25% and 25%, respectively.
READ MORE: The Push for Low- or No-Maintenance Industrial Machinery
It is not surprising that multiple respondents shared experiences that sounded like mine:
- “A locking dog on one of our designs failed due to unanticipated forces and poor recognition of stress concentrations.”
- “Too low reliability components affect the economic value of the whole machine if replacement in the field is not possible or realistic.”
- “Better wear and fatigue monitoring and warnings are much needed.”
- “Leakage and clamping issues on water hoses caused major service interruptions.”
- “Motor failures in harsh environments, like the desert in Algeria, make it essential that motor suppliers understand the critical factors involved in selection.”
These real-world snapshots highlight a common thread: Machine longevity is intimately tied to how easily machines can be maintained and repaired in the field. Designing for maintenance is not merely a convenience; it is necessary for reducing downtime, lowering lifecycle costs and improving overall machine value.
Perhaps designing machines that are easy to maintain is complex because there are multiple, sometimes conflicting, requirements. As engineers, you have to juggle component durability, system complexity, cost constraints and the integration of new technologies—all while seeing to it that technicians can access and service machine parts without excessive effort or specialized tools.
Add to this that field conditions and operational environments add variables that are difficult to predict in the lab. As another survey participant noted: “Motor failures in harsh environments necessitate supplier involvement in component selection to understand the nuances affecting durability and maintainability.”
Leveraging Resources, Cultivating a Maintenance Mindset
Last month’s survey also revealed what engineers find most helpful as they address design challenges:
- 68.75% rely on manufacturer specifications and data sheets as primary references.
- 43.75% turn to technical journals like Machine Design and other periodicals as well as design simulations/testing tools.
- 37.5% consult industry experts while 31.25% make use of CAD software.
Online forums and communities, as well as YouTube tutorials, also provide valuable support.
By leveraging the resources alongside emerging technologies like predictive maintenance sensors and IoT-enabled diagnostics, engineers can proactively address potential failures and ease maintenance burdens.
Integrating maintenance considerations into machine design isn’t just a technical challenge; it’s a shift in mindset toward building machines that support users throughout those machines’ full lifecycles. To help adopt this proactive maintenance mindset, there is a host of content on Machine Design that explores preventive and predictive maintenance strategies.
These approaches leverage data, real-time monitoring and analytics to catch issues before they become costly failures. If you don’t yet have full access to all of our site’s premium content, sign up today. It’s quick, easy and free.
Machine Design relies on you, our readers, to help shape our future content. Your experience and expertise matter greatly to us. To deepen our understanding of the real challenges and solutions in machine design maintainability, I invite you to participate in this quick survey that will help identify the latest trends, pain points and success stories that can guide future designs and innovations. Thank you in advance, and until next time, stay curious.
