Enhancing Worker Safety with Obsolete Spare Parts in Manufacturing

Using obsolete spare parts rather than replacing entire machines has proven to be both effective and compliant in many cases. However, businesses often overlook the critical aspect of employee safety. Part failures can lead to unanticipated consequences, creating hazardous work environments.

Balancing Manufacturing Efficiency with Worker and Chemical Plant Safety

When considering new machinery parts, it’s important to assess the potential hidden costs. While new parts might initially seem more affordable than obsolete ones, their compatibility with older equipment can be problematic. Integrating new parts might necessitate modifications or adjustments, inadvertently introducing new vulnerabilities and negating the initial cost savings.

It is crucial to perform a thorough cost-benefit analysis of both obsolete and new parts. This should include the initial purchase price as well as potential compatibility issues, ensuring an informed decision is made.

In the chemical processing industry, part failure is particularly concerning due to the presence of hazardous materials in high-pressure environments. Even minor malfunctions can trigger chain reactions, leading to the release of toxic substances, fires, and explosions.

In such environments, the failure of a single component can lead to a cascade of events, crippling the entire system. This chain reaction can cause extensive damage to interconnected machinery, halting entire production lines.

It’s well-documented that part failures, particularly in piping, account for about one-third of all equipment malfunctions in the chemical industry. Astonishingly, one-third of these failures escalate into fire or explosion incidents.

Sourcing obsolete parts can facilitate easier replacements for equipment with a high potential for failure, avoiding the need for system-wide replacements and reducing downtime. Ultimately, this approach minimizes manufacturing losses and enhances worker safety.

Improving Worker Safety Through Compliance

Strict regulations govern the chemical processing industry, such as the 2015 Control of Major Accident Hazards Regulations (COMAH). Given the emphasis on safety, companies must frequently test their equipment, which can make repairs more costly.

When legacy equipment fails and new parts are installed, the equipment must undergo retesting and recertification to ensure compliance. If system modifications are required, the entire production line may need retesting, leading to significant downtime and expenses. In such cases, using readily available, compatible obsolete parts can provide a practical solution.

Obsolete parts, which are no longer produced by the manufacturer, come in various forms, including second-hand or refurbished parts. These parts can reduce manufacturing downtime in the chemical processing industry as they are identical to the failed part and already compliant with regulations.

Automa.Net and Sourcing Obsolete Parts

Sourcing unused obsolete parts can be challenging due to their rarity. Automa.Net plays a crucial role here, providing access to obsolete spare parts from major automation suppliers like Omron, Mitsubishi, Indramat, and Siemens. Automa.Net ensures a global supply, often with same-day delivery and a full one-year warranty on all products.

With Automa.Net, manufacturers can obtain obsolete parts quickly, reducing downtime and maintaining system compliance. This approach frees manufacturers from the need to alter their systems, allowing uninterrupted operation. Chemical manufacturers find this method cost-effective and advantageous.

Automa.Net is dedicated to providing solutions that integrate seamlessly into existing systems, promoting a balanced and sustainable approach to industrial automation and worker safety.