The process of assembling and disassembling machinery requires accuracy, knowledge and experience, and adherence to specific procedures. Unfortunately, there are times when even competent technicians and operators make mistakes that can lead to damage to equipment and downtime. To avoid this, it is essential to plan the various stages of the work. The assembly and disassembly of machinery, especially when relocating, are tasks that require organisational skills.
Therefore, the most important thing is: plan, document and act methodically. And above all, check what are Mistakes when assembling machinery and how to avoid them!
Why is lack of planning the most common cause of problems?
Lack of planning is one of the main reasons why difficulties arise when working with machinery - whether during assembly, disassembly or relocation. In many cases, the problems are not due to the technology or quality of the equipment itself, but to ill-considered actions, makeshift solutions and haste. When there is a lack of strategy, procedures and coordination, even the most advanced machine can cause problems.
Every stage of working with the machine, from setting it up to commissioning, requires precision, knowledge and adequate preparation. Assembly and disassembly of machines are activities that should not be carried out "by eye". Inappropriate decisions made at the outset can result in costly downtime, damage to equipment and even risks to employee safety.
How to plan the assembly and disassembly of machines?
Ignoring the planning stage results not only in organisational chaos, but also in an increasing number of faults. Lack of preparation is also the most common cause of errors in the installation of machinery, which prevents it from functioning properly.
It is worth noting the most common problems when dismantling machinery. When there is no plan and disassembly is done in a haphazard manner, delicate components can easily be damaged, parts lost or the structure of the unit compromised. It also happens that the positioning of parts is not documented, making subsequent assembly difficult. The solution to this is checklist for assembly and disassembly of machines. In machine relocations where speed, precision and safety are important, such an inventory can significantly improve the start-up of a production line.
To avoid problems early on in the work, it is worth implementing a few simple but effective solutions. The most important of these are:
- Careful analysis of the technical documentation - even before installation or dismantling begins.
- Draw up a timetable - with clear roles and responsibilities.
- Create an inventory of parts - covering both technical and organisational elements.
- Team training - those carrying out the work need to be familiar with the procedures and the potential risks.
- Recording the process - taking photos and notes at each stage will make it easier to diagnose faults later or reassemble the machine.
A special case in point is relocation of machinery. Moving machines between halls or plants requires precise planning of logistics, securing parts, organising transport and preparing the new machine site. Here, oversights can result not only in downtime, but also in permanent damage.
How does incorrect installation affect the life of the machine?
Many users of industrial, construction or agricultural machinery ask themselves: why machines break down after assemblyEven though they were working perfectly just a short time ago? Very often, the source of the problem is not a manufacturing defect or physical wear and tear, but mistakes made during assembly.
It is worth remembering that assembly is not a formality, it is the foundation for further action. Assembling a machine is a process that requires not only knowledge, but also accuracy, patience and the ability to read technical documentation. Incorrectly assembled components directly affect the subsequent operation of the machine. The result can be faster wear of components, the occurrence of breakdowns or even a real risk to the operator's health.
Installation errors often make themselves known at the very first start-up. Typical failures due to incorrect installation is e.g:
- Loose mechanical connections - under-tightened bolts or nuts can cause vibration, axle misalignment and, as a result, accelerated component wear.
- Wrong installation sequence - omitting even one component or installing parts not in accordance with the instructions can lead to malfunction of the entire mechanism.
- Lack of lubrication - forgetting to use proper lubricants causes dry running surfaces to wear down and overheat quickly.
- Incorrectly set parameters - incorrect calibration after installation (e.g. clamping force, belt tension or guide settings) results in overload operation.
- Incorrect wiring - especially on electrical and hydraulic machines can result in a short circuit, leakage or complete unresponsiveness.
- No final test - skipping the trial run means that errors only become apparent during full operation, often at the least opportune moment.
And what if the machine doesn't work when assembled?
When a machine refuses to work after installation, it is worth keeping calm and approaching the problem methodically. First of all, check the technical documentation. Go back to the instructions and compare each step with the steps taken. Also analyse the connections and moving parts. Are all screws tightened? Are the parts not rubbing against each other? Is no detail missing? Examine electrical or plumbing installations. Make sure wires and hoses are connected according to the diagram, with no leaks or short circuits.
Look for signs of damage. Cracks, scratches or excessive wear and tear may indicate that the machine was poorly assembled or that overloading has occurred.
If you have not found the error and the machine still does not work, consult a specialist. A professional service will assess the condition of the machine and identify the error.
When is it worth calling in the specialists instead of doing the dismantling yourself?
Dismantling a machine is a process that requires not only the right skills, but also experience and technical knowledge. Many people with a DIY inclination may be tempted to do it themselves. However, in some cases it is far better to call in the professionals. Here are some key situations when this decision is worth making.
1. the complexity of the machine
Many industrial machines consist of many complex components. A complex machine or production line can cause many problems during disassembly. Specialists are experienced in handling specific types of equipment and know how to dismantle them safely. Acting on your own can result in damage that can be costly to repair.
2 Safety
Safety is a key factor when dismantling machinery. Many machines have components that can be dangerous, such as springs, hydraulic systems or electrical equipment. The wrong approach to dismantling can lead to serious injuries. Professionals are trained in safety and have the appropriate protective equipment, which significantly reduces the risk of accidents.
3 Equipment requirements
Dismantling a machine often requires specialised tools, which can be expensive and difficult to obtain. Professionals have the right equipment at their disposal, allowing them to complete the task efficiently and effectively. In addition, using the wrong tools when dismantling a machine yourself can lead to damage to the machine and increase the risk of accidents.
4 Regulations and standards
In some cases, dismantling machinery involves compliance with legislation and safety standards. In situations where the machine has been used in specific conditions, such as the chemical or food industry, it may be necessary to comply with the relevant regulations. Specialists are familiar with these regulations and are able to carry out dismantling in accordance with the applicable standards, ensuring legal compliance.
5. Disposal and recycling
Dismantling a machine often involves the disposal of various components. Specialists know how to properly segregate materials and where to return them, which is important from an environmental point of view.
6. time and cost savings
Although at first glance it may seem cheaper to dismantle yourself, there are often hidden costs involved. Taking the time to learn and experiment with disassembly can delay other important projects. If things go wrong, there may be additional repair costs. Outsourcing this task to a specialist saves time and money, and minimises the risks associated with potential mistakes.
