to do a good job of monitoring machine vibration and to fully reap the benefits, we must understand the answers to the above question. Monitoring the vibration characteristics of a machine gives us an understanding of the 'health' condition of the machine. We can use this information to detect problems that might be developing.
     

Why be concerned about the condition of a machine? Why not just continue to run the machine until it breaks down and then repair it? Operating a machine until it breaks down might be acceptable if the machine were a 'disposable' one. Most machines, however, are not 'disposable' due to their cost.

If we regularly monitor the conditions of machines we will find any problems that might be developing, therefore we can correct the problems even as they arise.

In contrast, if we do not monitor machines to detect unwanted vibration the machines are more likely to be operated until they break down.

Because machine vibration monitoring finds potentially damaging vibration, we can prevent problems arising and this saves a lot of time, money, and frustration. How? Below we discuss some common problems that can be avoided by monitoring machine vibration. These problems are worth avoiding as the costs of dealing with them are large and far exceed the cost of reasonably priced machine vibration monitoring programs.

(a) Severe Machine Damage
Machine vibration that is not detected early enough will often lead to severe machine damage requiring costly repairs or even total machine replacement. However, if the condition of a machine is monitored regularly, potential problems can be detected - and corrected - at an early stage when the repair required is simpler, faster, and cheaper. This is similar to our own health. Regular visits to a doctor help us to detect problems early and so avoid the large costs of remedying severe health damage.

(b) High Power Consumption

A machine that is vibrating consumes more power. As well as the power required for the machine to perform its intended function, additional power is also required to sustain the vibration. We can minimize this problem by regularly monitoring and maintaining the machine.

(c) Machine Unavailability

Because an unmonitored machine is more likely to break down, it is more often out of action. However, the cost of procuring and operating a machine is normally justified by its availability to process goods efficiently, or by its availability to convert raw material into cash. A machine should be consistently available to generate the money to justify its investment. Regular monitoring helps ensure that a machine is always available to generate money.


(d) Delayed Shipments
Because an unmonitored machine is more likely to break down, it is also more likely to cause delays in the shipping of goods. Customers have to wait and their payment is delayed. Customers could also cancel their order and stop doing business with us.

(e) Accumulation of Unfinished Goods
Because an unmonitored machine is more likely to break down, it is more often out of action. However, the cost of procuring and operating a machine is normally justified by its availability to process goods efficiently, or by its availability to convert raw material into cash. A machine should be consistently available to generate the money to justify its investment. Regular monitoring helps ensure that a machine is always available to generate money.

(f) Unnecessary Maintenance
To constantly ensure proper machine condition, some companies stop running machines according to predetermined schedules to adjust and replace parts regardless of whether or not the machines are malfunctioning. As a result, machines are often stopped unnecessarily to replace parts that are still good and to correct problems that do not exist. We can avoid such waste if the machines are regularly monitored and repaired only when necessary.

(g) Quality Problems
Sometimes a machine can be running into trouble even though it appears to be functioning normally. This is a dangerous situation. If not caught early, the problem could lead to poor quality products being made, large yield losses, rework costs, or worse still, warranty returns by irate customers. A machine that is regularly monitored is less likely to lead to such problems.

(h) Bad Company Image
We noted above that machines that are not regularly monitored can lead to shipment delays and produce goods of poor quality. Just one incident of shipment delinquency or product defect is often enough to seriously strain or even end relationships with customers. A bad company image associated with shipment delays and poor quality is something to be avoided. For a relatively small cost, machine vibration monitoring can protect customer relations and thus profitability.

(i) Occupational Hazards
Due to the noise and shaking they create, vibrating machines can cause occupational hazards and human discomfort. Human discomfort results in a loss to the company as workers who feel unwell will not be fully productive. Also, unexpected machine breakdowns leave workers with no work, and production planners with frustration.

Summary
In this article we described machine vibration and discussed the benefits of monitoring machines on a regular basis.

Machine vibration is simply the back-and-forth movement of any machine or machine component, and is generally caused by repeating forces acting on the machine, loose machine parts, or resonance (a repeating force with a rhythm matching the natural oscillation rate of the machine).

We identified the reasons for monitoring machine vibration regularly, as well as the consequences of not doing so. By regularly monitoring the vibration characteristics of a machine we can detect and correct machine problems as they arise. By correcting machine problems early we avoid many unpleasant and costly problems, some of which involve customers. The cost of failing to monitor machine vibration far exceeds the cost of implementing a vibration monitoring program.

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