Stages on the Path to Equipment Breakdown
• Stage 1: Latent minor defects
Though difficult to see or hear, the machine’s rotating and moving parts are operating under
increasing friction and its fastened parts are getting a little looser. These and other subtle
defects characterize the first stage of equipment deterioration
• Stage 2: Apparent minor defects
The same defects described in the first stage have now become somewhat noticeable to the
eye or ear. In addition, the machine may be vibrating more, making more noise, and leaking
small amounts of oil, water, or air. But none of these defects are major enough to impair the
machine’s functioning.
• Stage 3: Performs below expectations
At this stage, it has become difficult to get the machine to perform with the desired precision
and within the specified tolerances. The machine is turning out products with varying quality
or not performing as specified, and suddenly it needs more adjusting than it use to require. It
can no longer keep up with quality standards and is producing lower yields or performance
expectations.