{"id":9664,"date":"2023-03-08T01:02:37","date_gmt":"2023-03-08T08:02:37","guid":{"rendered":"https:\/\/limblecmms.com\/?p=9664"},"modified":"2025-05-30T13:04:07","modified_gmt":"2025-05-30T19:04:07","slug":"functional-failure","status":"publish","type":"post","link":"https:\/\/limblecmms.com\/blog\/functional-failure\/","title":{"rendered":"A quick guide to functional failures: definition, examples & common causes"},"content":{"rendered":"

[vc_row kd_background_image_position=”vc_row-bg-position-top”][vc_column][vc_column_text]Functional failures are a problem in every industry. It\u2019s a silent way to lose money, waste time, and squander precious manpower. You need to understand it \u2014 so you can prevent it.<\/span><\/p>\n

We\u2019ll show you what functional failure is, explain the difference between functional and partial failures, and share the most common causes behind equipment failures.<\/span><\/p>\n

What is functional failure?<\/span><\/h2>\n

Simply put, an asset has experienced functional failure if it can no longer perform its function.\u00a0<\/span><\/p>\n

The term \u201cfunctional failure\u201d can refer to a wide range of problems, symptoms, and impacts.\u00a0<\/span><\/p>\n

<\/span>The most extreme example is a machine that won\u2019t turn on or run at all. A <\/span>lighter<\/span><\/i> version of functional failure is when a machine doesn\u2019t have the same yield, speed, or throughput it used to have.<\/span><\/p>\n

In fact, anything short of peak performance is considered a functional failure.\u00a0<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row content_placement=”middle” kd_background_image_position=”vc_row-bg-position-bottom” kd_top_separator_style=”skew-left” kd_top_separator_height=”separator-height-small” kd_bottom_separator_style=”skew-left” kd_bottom_separator_height=”separator-height-small” kd_top_separator=”true” kd_bottom_separator=”true” css=”.vc_custom_1682969636891{margin-bottom: 40px !important;padding-top: 120px !important;padding-right: 40px !important;padding-bottom: 50px !important;padding-left: 40px !important;background: #dde4e8 url(https:\/\/limblecmms.com\/wp-content\/uploads\/cta-laired-hex-4.webp?id=9077) !important;background-position: center !important;background-repeat: no-repeat !important;background-size: cover !important;border-radius: 0px !important;}” css_tablet_landscape=”.vc_custom_1682969636891{padding-bottom: 80px !important;}” css_tablet_portrait=”.vc_custom_1682969636891{padding-bottom: 80px !important;}” css_mobile=”.vc_custom_1682969636892{padding-bottom: 80px !important;}”][vc_column][vc_row_inner kd_background_image_position=”vc_row-bg-position-top”][vc_column_inner]

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Total functional failure vs partial functional failure<\/span><\/h2>\n

We can break down a functional failure into two distinct categories:\u00a0<\/span><\/p>\n

    \n
  1. Total functional failure:<\/b> The machine doesn\u2019t work at all.<\/span><\/li>\n
  2. Partial functional failure:<\/b> The machine still works, but it can\u2019t achieve peak performance.<\/span><\/li>\n<\/ol>\n

    \"Explaining<\/p>\n

    Total functional failure is impossible to miss as it makes the asset unusable.<\/span><\/p>\n

    On the other hand, without tracking production metrics, spotting a partial failure can be tough.\u00a0<\/span><\/p>\n

    Imagine a metal skiver that needs to consistently cut your product into slices of 1.00 inch, plus or minus 5 mils (5 thousandths of an inch). A partial functional failure could manifest as a dull blade with wider tolerance, sending the product outside of your predefined specs.\u00a0<\/span><\/span><\/p>\n

    If you don\u2019t measure the thickness of your product regularly, it might be a while before you figure out that your asset needs <\/span>corrective maintenance<\/span><\/a>.<\/span><\/p>\n

    Examples of functional failures in industrial equipment<\/span><\/h2>\n

    To understand functional and partial failures better, let\u2019s go through a couple of examples.\u00a0<\/span><\/p>\n

    This time, imagine you\u2019re working in an injection molding facility. There, you have:<\/span><\/p>\n