Supply chain issues force manufacturers to maintain or even increase production volumes. But how can you maintain production if you're experiencing supply chain issues? Having trouble sourcing raw materials is one thing, but what about the industrial components used to run production lines? What happens if these parts fail and halt production?
Luckily, there's a simple and reliable solution: use equipment restoration services to get your equipment back in top working order and get production back on track.
Why repair assets?
Unfortunately, industrial components fail sooner or later, and purchasing new parts isn't always possible or the best course of action. Maintaining an adequate supply of spare parts is an important strategy for maintaining components in working order, but there are many other factors to consider when deciding whether to repair equipment:
Compare the cost of equipment repair with the cost of purchasing new equipment. It's often more cost-effective to repair what's already in place, but when you multiply the savings by dozens of non-functioning devices per year, the difference in cost between repair and purchasing new equipment can really add up. How much can you save if you repair all your components?
Consider warranty options. You should always check whether your part is covered by the manufacturer's warranty or an extended warranty, as you may miss out on free repairs. Also, be sure to understand the manufacturer's warranty policy, which often provides a multi-year repair warranty compared to a new part, which may only have a one-year warranty. A longer warranty can save you money on future repair costs.
Check your order lead time. If there are supply chain issues, repairs may be faster than waiting for a new order.
Repair may be the only (and best) option for old, obsolete components that are no longer in production. When upgrading to the latest equipment doesn't support existing production lines, or upgrade options are limited by the use of obsolete components, you're better off using high-quality remanufacturing services from the OEM. Using "gray" stock, which may not be certified or lack the latest software/firmware, is risky.
Consider your company's sustainability goals, as repair and refurbishment support the circular economy. With the growing need to produce less waste, component repair not only extends the lifespan of equipment but can also help your company achieve sustainability goals by keeping waste out of landfills, reducing carbon emissions, saving money, and generally promoting a circular economy.
If you do decide to have your device repaired, make sure you're working with a reputable repair and/or refurbishment service provider . The equipment should be returned repaired and ready for production. A reputable provider will guarantee the quality of their service, use genuine components, and promptly replace defective or outdated components. They will also test the device as they would a new product.
Do you have a renovation strategy?
Of course, you can send parts for repair as they fail, but in this case, you're missing out on the benefits of a strategy rather than handling individual operations. To reduce overall maintenance costs, minimize effort, and maximize production uptime, consider the following steps to formalize an overall maintenance and repair strategy :
Identify repairable equipment and components. You're unlikely to send a part in for repair if you don't know how repairable it is.
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What will motivate your team to consider repair over disposal?
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Can you label your repairable parts?
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Should CMMS (Computer Maintenance Management System) or other system tools be used to indicate which parts need repair and which suppliers should be contacted?
Assess the scope and potential of the renovation.
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What percentage of repairable units in your facility do you currently repair?
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How much more can you repair?
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What will be the savings on maintenance and repairs if you maximize the number of repairs?
Find out and organize warranty information . Almost every item comes with a manufacturer's warranty, and some parts may be covered by warranty coverage for the duration of use or repairs.
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Do you have the means to track which assets are still under warranty to avoid spending unnecessary money on repairs?
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Additionally, if you are dealing with high-value or production-critical assets, would it be a good idea to have an extended warranty to protect your investment?
Find the right partners for your repair services . Evaluate current repair providers, product manufacturers, and other options. Who can provide repair services? Also, don't limit yourself to price; make sure you consider the quality of repairs, repair warranties offered by each provider, and additional benefits.
Often, repairs from the original manufacturer can include additional benefits such as firmware updates, testing, and better long-term warranties, which can reduce the overall number of repairs.
Consider repair agreements to ensure cost-effectiveness, streamline, and expedite the process. How much time and effort does each repair require, and are you getting the best price? A repair agreement can lead to predictable billing, expedite the process, and reduce repair costs. Ensure you understand your current and future repair needs, and then explore vendor agreements that will help you save on future repairs. Check with vendor partners to see what repair contracts or discounts are available, and select one or two primary vendors for the bulk of your repairs to ensure efficient use of your repair funds.
Ensure staff buy-in and successful implementation of the repair strategy . After you've spent time calculating the benefits and implementing the strategy, the worst thing that can happen is that no one follows through. How will you ensure your employees send products for repair rather than scrap? Communication with your team is crucial to effectively launch and monitor the strategy's implementation.
Of course, you need to perform regular preventative maintenance to prevent breakdowns and extend the lifespan of your components. Ensure all standard preventative maintenance tasks are added to your CMMS software and that your maintenance team completes them on time. If you lack the time or expertise to perform preventative maintenance in-house, consider outsourcing to the manufacturer or other service providers.
Plan to modernize your operations before a significant portion of your installed base of industrial automation becomes obsolete and is no longer produced or supported. While repair services can maintain and extend the life of your products for years, they are no substitute for upgrading to newer components and equipment.
With a reliable, quality refurbishment partner, you can restore your products to their original working condition, extend their lifespan, and achieve greater equipment uptime.
Contact us for a consultation.
Download a checklist for preparing a repair strategy for your equipment and components.