Preventing Metal Component Failures in Industrial Projects – Any Tips?

[bilal68]

Hey everyone,

I’m hoping to get some advice from folks here who have dealt with industrial fabrication or maintenance. In the past few months, we’ve run into a few cases where metal parts on some of our equipment failed much earlier than expected, things like brackets bending, welds cracking, or custom components just not holding up under stress. It’s got me wondering: What are some best practices you use to prevent premature metal component failure in industrial settings? Do you always specify certain grades of steel, request extra quality checks, or work with specialist fabricators?

We’re now looking for ways to ensure better durability and reliability in future projects. I came across Kirmell while researching fabrication companies that emphasize precision and quality. Has anyone here worked with them or have experience with other suppliers that go the extra mile for quality control?

Would really appreciate any insights, recommendations, or “lessons learned” so we can avoid more unexpected breakdowns!


Thanks in advance!

 

[Gr8blu]

Component design is always based on assumptions. These typically include assumptions about the material's properties (mechanical, electrical, chemistry, dimensional tolerance, etc.) It is also based on assumptions about the intended usage - which includes how the piece is to be manufactured, how it is assembled to other parts, and what it happens to it when it leaves the facility.

If the material used isn't the material specified, then quality checks (or maybe a change in suppliers) is warranted. If the manufacturing process is introducing extra stresses into the design, a process evaluation (and probable modification) is required. If it is simply that the in-house team doesn't know the "right way" to do something, it boils down to having the right tools for the job and the right training.

From the description - the OP needs to look at what is happening and go through a PROPER root cause failure analysis and figure out where the trouble is occurring - and then develop a plan to overcome it. Be aware - the first thing that crops up is only the "weakest link" - failures are going to occur, so there may be something else that will appear immediately after you think you've "fixed" the issue!

 

[3DDave]

Including that link makes this look like an advertisement. The failures you describe have to do with design, not fabrication, so the inclusion is even more suspicious.

Clever spam, but still spam.

 

[Stick.]

This is a massively open ended question and there's no single, easy answer. Really, for your prior failures, you need to properly analyze the failure and figure out why the component failed, and then change whatever is necessary to prevent it in the future. Maybe the design was inadequate, maybe there was a manufacturing issue/flaw, or maybe the component was used incorrectly/beyond it's design limits. Figure out which of those apply, and then figure out a fix for any of them.

Also, I agree with 3DDave that this smells a bit spammy. I have other thoughts, but don't feel like wasting time typing them out if you're just subtly trying to drum up business for the company you linked to.

 

[mfgenggear]

Op
This not a simple answer.
#1 ) correct designs criteria, metallurgical, tensile properties.,correct geometry.
#2) applicable specifications for control of
The manufacturing and quality. The required
Inspection sampling of the components for dimensional control.
#3) your company and the suppliers with a quality system integrated, and followed.
#4) this has to be flowed down from the top management, or it will not succeed.
#5) retaining of all certifications, procedures ,
For a period of time.

#6) sop and operation planning is important for review for failure analysis.

 

[dgeesaman]

We’re now looking for ways to ensure better durability and reliability in future projects. I came across Kirmell while researching fabrication companies that emphasize precision and quality. Has anyone here worked with them or have experience with other suppliers that go the extra mile for quality control?

Would really appreciate any insights, recommendations, or “lessons learned” so we can avoid more unexpected breakdowns!

Avoid buying machinery from companies who try to advertise like this.