Your Failure Analysis Program

If you’re an owner, operator, or manager in an industrial setting, it’s impossible to be everywhere at once. You have to rely on your personnel and team to make sure machinery and operating systems are being closely monitored – and updated.

Creating a Failure Analysis Process

However, it can be a challenge keeping up with everything. Sometimes it can be due to the lack of time in the course of a day or week. 

Regardless of where the problem lies, you can take steps to tighten up the process, and ensure that the chain of command and communication has been established correctly, and that everyone knows how it works, and how to move information from one party to another.

A failure analysis program can be a useful tool – and while it may sound complicated and complex, it doesn’t have to be. 

It can be easy to fall into the trap of overthinking a failure analysis program because you want it to be detailed and comprehensive, but if it becomes too complex, your program can cause more problems than it solves.

Start with these basic categories:

  • Who?
  • What?
  • When?
  • Where?

Answering these questions can help you begin to organize your process – and while it may seem too broad, you can obtain a clear picture of responsibilities, the personnel involved, and determine if the right skill sets are in place.

From this point you can begin to add more detail to the failure analysis process, and focus on more specific factors.

Common Types of Failures

The factors that contribute to component and equipment failure can range from overload to the operating environment. Missed maintenance checkups can be another culprit. 

For instance, internal drives and motors are the workhorses of a system, and experience a great deal of vibration, high temperatures, and components that have short life cycles. Lubricants can break down over time and allow for increased friction.

Decide how to counter these problems, and confirm how often maintenance protocols are being followed, and if they’re recorded and shared.

Methodology at Work

Establishing the process is the goal of this step. While each operation can vary depending upon what’s being manufactured, most of these steps can be applied to your situation.

  1. Diagnosis
  2. Background data collection
  3. Component inspection
  4. Confirm physical failure
  5. Determine human root causes

Each of these steps produces information that can be collected and reviewed, but in order to work they must be consistent and enforced. Don’t allow employees to customize these steps, but listen to their feedback and suggestions.

In cases where production is ramped up due to customer demand, internal systems can become overworked and prone to failure. There might be a need for adding additional parts to an assembly line so the workload is more evenly distributed.

Operator error and the “human factor” should be accounted for. You may have employees who aren’t qualified or are taking matters into their own hands. 

Be honest in your assessments and refer to concrete data: employee reviews, production output, and maintenance records are several examples.

Finally, write a course of action for how the problem will be properly fixed via increased maintenance, locating parts that may need to be fixed, or evaluating the need for replacing the equipment in question.

Failure analysis programs aren’t finished overnight, they require collecting information from multiple sources, analysis, and then agreeing on a final version that has buy-in from everyone involved – from front line personnel to upper level management.

Following your failure analysis program can help solve problems, save money, and contribute to a more successful operation. 

ACS Can Help

As your failure analysis program produces results, you may find that certain components or parts might need to be repaired instead of completely replaced.

When that happens, contact the experts at ACS, we offer a free evaluation and repair quote for a variety of electronic repair and services.

Repair can often save as much as 80% of the cost of buying a new piece of equipment.

  • Most repairs are back in your hands in 7-15 days after approval.
  • Our Rush Repair Service ships in just 2-5 days after approval.
  • We Guarantee Our Repairs With A Full Two-Year Warranty.
  • For a Free Evaluation, use our RMA Form link or Contact Us. You can also reach us at 800-605-6419 and speak to someone on our customer support team.

man works on equipment repair to save money

How Industrial Equipment Repair Saves Your Business Money

Many business owners know that as soon as a needed piece of equipment goes down, it can affect the whole company. If a required tool is no longer working, the employee cannot do their job, which sets a project back, affecting profitability. 

To avoid profit loss and other issues down the road, consider promptly repairing your industrial equipment so that the chances of running into bigger problems down the road or having to buy new are significantly reduced. It may seem like a costly investment, but it will actually save your company money in the long run. 

Increase Efficiency

When every aspect of your business is running smoothly, the efficiency of your operations increases; but when a crucial machine suddenly goes down, your business begins to lose money. Buying a new machine can be costly and often takes longer to get to you than it does to simply have the existing piece of equipment repaired.

Repairs are much more likely to be a quick, efficient solution to your problem than buying new.

Keep Customers Coming Back 

When your company’s lead times are accurate and your employees are happy, your company will thrive. With that in mind, when a product is made and delivered on time, it builds trust between you and your customers. . 

When your business consistently provides the same service, your customers will know that they can count on you to get the job done. Happy customers are essential, and great customer service will keep them coming back. 

Having your industrial equipment repaired means that you’ll be more likely to keep your promises to customers and clients. You won’t have to cut corners or potentially wait weeks to months for a new machine so you can fill an order.

Increase Lifespan of Equipment

This one may seem obvious, but it’s really the most important point of all of them. The longer that your equipment lasts, the more profit you can make off of it. Spending a fraction of the cost to keep your original equipment working is nearly always preferable to dumping thousands into new equipment – especially if we find that the issue is just a simple fix.

Reduce Production Downtime 

When a piece of equipment goes down, and an employee cannot get their job done, you are losing money on both the employee’s wages and the products that cannot be produced. To avoid any downtime, be sure that your equipment is always up and running correctly. If you need assistance, ACS Industrial is here to help.

Are you in a jam and need a fast repair service for your damaged equipment? ACS takes your need for fast, reliable service to heart. 

You may have a manufacturing line down, and you have people yelling for help with production, which might be costing everyone time and money and causing unnecessary stress.

If you need assistance, contact ACS Industrial today. Visit our website to fill out our contact form, or give us a call at 800-605-6419

6 Top Tips to Extend the Life of Your Power Supply

ACS Repairs Lambda Power Supplies

Power supplies – they are ever present for most of us, both at work and at home.  They come in all sizes and levels of quality and for myriad purposes.   Even so, they have some things in common – their universal dislike of moisture, heat, and dirt – which I like to refer to as the electronic axis of evil.

Here are 6 top tips to extend the life of your power supply and avoid having to replace or repair your power supply:

1.  Number one tip, by far, is to buy the best power supply you can afford that is adequate for the load.  A power supply is absolutely one of those things where you get what you pay for.  If you opt for a cheap unit, it may not supply adequate current even when used within nominal power ratings.  Power supplies don’t like to die alone either – they usually take down other components with them when they go.  Buying a cheapie power supply will cost you in the end!

2.  Know the MTBF…that is your “Mean Time Between Failures” rating of your power supply.  To do this you can check the electrolytic capacitors used in your PSU.  Capacitors have a limited life that affects the life span of the power supply.  Either ask your sales rep for this data or check on these:

  • Size of Capacitor – bigger is usually better
  • Operating Temperature – the hotter your work environment, the shorter the power supply’s life
  • Component Rating – how much voltage the unit can safely handle

3.  Make sure the area around the power supply is well ventilated.  (Remember…power supplies hate excess heat.)

4.  Keep the vent and fan clean and free of lint, grease, dust or whatever it is that accumulates in your plant or office.  This may mean cleaning it often, at least once a week.

5.  Minimize vibrations.

6.  Don’t get your power supply wet – ever.  Unless it is made to operate in a wet environment.

If your power supply does quit on you, know that most power supplies are repairable.  Even those that are choked in grease and dirt (as they often are) can usually be revived.  If your unit is still under warranty call the power supply manufacturers to get assistance. If your power supply is out of warranty, you can still get power supply repairs from a reputable industrial electronic repairs shop.  However, none of this applies if you bought one of those no-name, super-cheap power supplies from some mystery website.  If this is the case, your best and cheapest (really!) course of action is probably to replace it with a better quality power supply.

About the Author: ACS Industrial Services is an independent industrial electronic repair center providing repairs for all types of industrial electronic equipment and most all manufacturers including circuit board repairs, logic board repairs, repairs for industrial power supplies, drives, servo motors, CNC equipment, encoders, monitors and touchscreens, test equipment, and much more.  Rush Service is available and a comprehensive 2-Year Warranty covers most repairs.  The customer service team is available to answer your questions and help solve your industrial electronic repair problems. You can reach them by calling 800-605-6419 or going to

Tips for Buying Used Industrial Electronics

Vickers S40 CNC controllerBuyer beware! Caveat emptor….you’ve heard it many times.  And when buying used industrial electronics (or anything for that matter) be hyper alert for problems.  This 1986 Vickers controller S40 was purchased second hand for use in a sheet metal fabricating shop.

As it turned out, the controller did have more than a few problems.  Soon after purchase the Y Axis controller was losing Y values during a run which the customer kept to a minimum by cooling with an external fan.  Months later the unit was failing on start up. When this unit is working properly the L5 L6 L7 all light up ready to work but the customer ended up with just the L4 lighting.

On top of all that, it appeared that previous repairs had been attempted which had not solved the problems.  In fact, the “repairs” themselves were the biggest problem.  Because it was purchased used, our customer had no idea what the history was with this unit.   It was just a hot mess, literally.

Bad times at this Australian sheet metal fabrication shop.  Luckily, this unit was repairable, and just as importantly, worth repairing.  After disassembling the unit and identifying the problems repairs were performed including repairing the switcher supply circuitry and replacing all the supply caps and buss caps.   All of the components were checked including the IGBTs and any that were aging were replaced. The unit was thoroughly cleaned, reassembled and tested before shipping back to the customer in working order.

After receiving the repaired unit back in Australia, our customer gave our team a 5 STAR review and had this to say:  “repaired unit works as it should, many thanks”  – John .  We are glad this story turned out so well!

Not all stories do turn out so well.  Buying used electronics can save a lot of money, or sometimes not.  It’s not necessarily that the seller is trying to get one over on you (although they may), it’s just that sometimes the problems may be unknown.   Before purchasing used industrial electronics do your due diligence to the extent possible including:

  • Inspect the condition
  • Test the unit if possible
  • Confirm its authenticity
  • Make sure there is a warranty, or at least know the return policy before purchasing
  • If it seems too good to be true, it probably IS, so walk away and keep looking

If the good deal you bought turns out to be a possible dud and you end up needing an industrial electronic repairs center for your damaged controller or other industrial electronics, check first to see if your equipment is still under warranty and if so, contact the OEM about repairs. If it is out of warranty, contact an independent industrial electronic repair center to find out if they are a good fit for your company and your particular repair needs. They should offer free evaluations for your damaged equipment and, if needed, a free quote for repairs (no bench fees!).  They should also provide repair reports if requested and a good warranty of at least one year that covers both parts and labor.

About the Author: ACS Industrial Services is an independent industrial electronic repair center providing repairs for all types of industrial electronic equipment and most all manufacturers including power supply repairs, circuit boards, drives, servo motors, CNC equipment, encoders, monitors and touchscreens, test equipment, and much more.  Rush Service is available and Two Year Warranties cover most repairs.  The customer service team is available to answer your questions and help solve your industrial electronic repair problems. You can reach them by calling 800-605-6419 or going to

Power Supply Repairs for TV Stations

Get Expert Power Supply RepairsHey, so what’s going on in all those television stations around the country?  For some reason we have been seeing a huge increase in damaged power supplies sent in for repairs from television stations.  Maybe things are getting a little rough out there in TV land?

As it turns out, these power supplies are pretty repairable and we’re pretty darn good at repairing them.  So never fear, you will be watching your favorite TV shows and sports games this weekend (The real NFL refs are back!! Yes!!) without interruption.

Need to get power supply repairs fast?  Click here or short cut to these popular TV station power supplies below:

Sony Power Supply Repairs

Cherokee Power Supply Repairs

Pioneer Magnetics Power Supply Repairs

ACS Industrial Services has got your back!  Let us get you back up and running!

Simplified On-line Repair Form Makes Getting Electronic Repairs Easy

Have you tried our new, simplified on-line repair form yet?  It’s been live for a few weeks and WOW is all we can say!  Wish we’d done it sooner.

The process is working great and our customer surveys are producing comments like this:

  • “Easy as pie. Nothing more needed.”
  • “I really do not see how you could have made it any more easier.”
  • “This form was super-easy to understand and complete. My suggestion is “Don’t do anything to improve; it works perfectly as is.””

We boiled everything down to the basics to make it a whole lot faster and easier on you.  We’ve all gotten stuck in annoying on-line forms and it’s just really irritating.

If your equipment is down and needs repair we know you are ALREADY irritated. We wanted to reduce the irritation factor and keep the process simple and straightforward– that is, getting your electronics repaired and back to you as fast as possible for the best price possible.

Need repairs?  Give our new on-line repair form a try by clicking here.  Need more information about our industrial electronic repair services?  Click this link:  ACS Industrial Services.