On a hot summer day, when the entire plant comes to a halt, a heavy silence fills the air. It’s not the silence of a breakdown, but the perfect moment to look closer at the line itself. Thanks to the service's efforts, hidden faults are revealed in empty halls, even before major breakdowns occur. Unfortunately, our client decided to cancel the audit, with serious impact.
We'll share with you a true story in which a lack of maintenance transformed a well-organized and efficient facility into a place rife with anxiety, stress, and tension. This story serves as a warning that an audit is a chance to avoid extended, unplanned downtime.
The risk of failure has become a fact
After scheduling an inspection, the client informed us of their cancellation. According to the team, the equipment operated without any issues and did not indicate an urgent need for inspection.
The lack of inspections meant that the overall condition of key system components was not verified and the risk of potential failures was not assessed, which only increased the risk of prolonged downtime. The lack of audits soon led to serious consequences.
Two weeks later, a dozen or so hours before the long weekend, the production line was operating without disruption until two 150 kW Siemens Sinamics G150 inverters suddenly exploded. Their shutdown halted a key section of the process. The resulting downtime affected the entire production chain, blocking subsequent production stages.
A breakdown in equipment could result in significant financial losses while the machines are idle. Furthermore, production delays would immediately translate into difficulties with on-time deliveries to customers, which in turn could result in contractual penalties and weakened relationships with key partners. Such situations demonstrate how costly abandoning prior control can be.
On the same day, right after reporting the failure, our team organized the transport of the device to our center. Due to the large size of the inverters, a crane was required. Thanks to full mobilization, the device was restored to full operation in a relatively short time, but the canceled audit resulted in several days of downtime at the client's company.
The scope of work performed included, among others:
Cabinet 1:
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replacement of a burnt-out power block
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maintenance of a functioning power block and replacement of some capacitors on the control boards
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mechanical repair of rectifying circuit thyristors
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mechanical straightening of dc bus
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replacement of bearings in turbines
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improving connections in cables
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comprehensive cleaning and maintenance of the entire
Cabinet 2:
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maintenance of both power block
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mechanical repair of one of the dc bus
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replacement of turbine bearings and starting capacitors
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comprehensive cleaning and maintenance of the entire
Don't wait for a breakdown, take advantage of planned downtime
The situation described shows that the performance of a full audit should not be postponed.
Our experience shows that a planned downtime is the ideal time to inspect a production line. First, an audit during this period allows for the detection of potential faults before normal operation resumes, preventing unexpected failures and costly downtime. Thoroughly verifying the technical condition of inverters, drives, and control systems increases the safety of personnel and equipment, minimizing the risk of accidents. It's also time to optimize processes and implement minor improvements that will increase efficiency once production resumes. Systematic use of downtime for inspections builds trust with customers and contractors, demonstrating commitment to timely delivery and continuity of supply. This ensures that every summer line shutdown becomes not a disruption, but a strategic step towards stable and safe production.
