Improving Factory Automation Reliability

Modern manufacturing depends on reliable machinery, electrical systems and industrial automation. From production lines and conveyor systems to pumps, motors and control panels, every component plays an important role in keeping operations running smoothly.

However, even well-designed automation systems can experience problems over time. Component wear, outdated control systems, electrical faults and inadequate maintenance can lead to unexpected breakdowns, production delays and increased operating costs.

Improving factory automation reliability is therefore essential for manufacturers looking to maintain consistent production, reduce downtime and get more value from their existing equipment.

In this guide, we explore practical ways to improve automation reliability and explain how a structured maintenance and engineering approach can help keep industrial operations running efficiently.

What Is Factory Automation Reliability?

Factory automation reliability refers to the ability of automated machinery, control systems and electrical equipment to perform their intended functions consistently over time.

A reliable automation system should operate with minimal unexpected interruptions, maintain consistent performance and allow faults to be identified and resolved efficiently.

This involves more than maintaining individual machines. It requires a complete understanding of how electrical infrastructure, PLCs, HMIs, industrial drives, sensors and mechanical equipment work together.

For manufacturers, improving reliability means taking a proactive approach rather than waiting for equipment to fail.

7 Ways to Improve Factory Automation Reliability

1. Implement a Preventive Maintenance Programme

One of the most effective ways to improve factory automation reliability is through regular preventive maintenance.

Waiting until equipment breaks down can result in expensive repairs, production interruptions and additional pressure on maintenance teams.

A structured maintenance programme helps identify potential problems before they develop into major failures.

Key maintenance activities include:

• Inspecting electrical panels, connections and wiring.
• Checking motors, gearboxes and industrial drives.
• Identifying overheating and abnormal operating conditions.
• Inspecting sensors, actuators and control components.
• Reviewing PLC and HMI system performance.
• Checking cooling systems and ventilation.
• Maintaining equipment inspection and service records.

Regular inspections provide better visibility into equipment condition and help maintenance teams plan repairs and replacements.

For further guidance on planning maintenance and using competent personnel, see the Health and Safety Executive’s maintenance of work equipment guidance.

2. Maintain and Upgrade PLC and Control Systems

Programmable Logic Controllers (PLCs) are central to many industrial automation systems. They control machinery, production sequences, safety functions and communication between different equipment.

However, older PLCs and control systems can become increasingly difficult to maintain.

Common challenges include:

• Obsolete PLC hardware and unavailable spare parts.
• Outdated software and unsupported operating systems.
• Communication problems between control devices.
• Inconsistent system performance.
• Limited access to technical support.

Regular PLC maintenance, software backups and control system assessments can help reduce these risks.

Where necessary, upgrading legacy PLCs and HMIs can improve system supportability, simplify troubleshooting and provide a more sustainable automation solution.

3. Monitor Industrial Drives and Motors

Industrial motors and drives are essential components in manufacturing environments. They control the movement and speed of machinery, pumps, conveyors and production equipment.

A problem with an inverter, variable frequency drive (VFD) or motor can affect an entire production process.

To improve reliability, manufacturers should regularly:

• Inspect drives for overheating and contamination.
• Check electrical connections and terminal conditions.
• Monitor motor operating temperatures.
• Review drive fault histories and alarm records.
• Check cooling fans and ventilation.
• Verify motor parameters and operating conditions.
• Assess ageing or obsolete drive equipment.

Where equipment is approaching the end of its service life, a drive retrofit or replacement may be more practical than repeated repairs.

4. Carry Out Regular Electrical Inspections

Electrical faults are a common source of unexpected equipment problems in industrial environments.

Loose connections, damaged cables, deteriorating insulation and overheating components can affect the performance and safety of automated systems.

Regular electrical inspections should include:

• Control panel condition assessments.
• Inspection of electrical connections and terminations.
• Cable and wiring inspections.
• Checking protective devices.
• Thermal inspections where appropriate.
• Verification of earthing and bonding arrangements.
• Identification of electrical installation defects.

Electrical maintenance should be carried out by appropriately competent personnel and in accordance with applicable UK requirements and site procedures.

Identifying electrical issues early can help prevent equipment failures and reduce operational risks.

5. Improve Fault Detection and Diagnostics

When automation equipment stops working, identifying the actual cause of the problem is essential.

Repeatedly replacing components without investigating the underlying fault can increase maintenance costs and lead to recurring breakdowns.

A better approach involves structured fault finding and diagnostics.

Maintenance teams should review:

• PLC fault codes and diagnostic information.
• HMI alarms and historical events.
• Drive fault histories.
• Sensor and actuator feedback.
• Communication network performance.
• Electrical supply conditions.
• Equipment operating sequences.

Accurate fault diagnosis helps engineers identify the source of a problem and implement appropriate corrective action.

It also provides useful information for future maintenance planning.

6. Keep Automation Software and System Backups Updated

Hardware maintenance is important, but software and configuration management are equally essential for factory automation reliability.

PLC programmes, HMI configurations, drive parameters and industrial network settings should be properly documented and backed up.

Without reliable backups, recovering from a controller failure or accidental programme change can become unnecessarily difficult.

Good practices include:

• Maintaining secure PLC and HMI programme backups.
• Recording software and firmware versions.
• Documenting drive configurations and parameters.
• Keeping updated electrical drawings.
• Controlling software changes.
• Testing restoration procedures where appropriate.

These steps help reduce recovery time and support more consistent maintenance.

7. Plan Equipment Upgrades Before Failure Occurs

Many manufacturers continue operating equipment that has been in service for years.

While replacing every ageing component is not always necessary, continuing to operate obsolete or unsupported equipment without assessing its condition can create avoidable risks.

A planned upgrade strategy should consider:

• Equipment age and condition.
• Availability of replacement components.
• Manufacturer support and obsolescence.
• Frequency of breakdowns.
• Production criticality.
• Integration requirements.
• Long-term maintenance costs.

A phased upgrade approach can help manufacturers modernise existing systems while managing operational disruption and investment requirements.

Common Factors Affecting Factory Automation Reliability

Several factors can influence the reliability of industrial automation systems.

Understanding these issues allows maintenance teams to prioritise inspections and allocate resources more effectively.

Why Regular Automation Health Checks Matter

An automation health check provides an opportunity to assess the condition of critical industrial equipment and identify potential maintenance or upgrade requirements.

Rather than focusing on a single component, a structured assessment can examine the wider automation environment.

Depending on the equipment and scope, an assessment may include:

• PLC and HMI condition reviews.
• Industrial drive and motor inspections.
• Electrical panel assessments.
• Control system obsolescence reviews.
• Software backup checks.
• Industrial network condition assessments.
• Identification of maintenance and upgrade priorities.

The findings can help manufacturers make informed decisions about maintenance planning, equipment replacement and future automation improvements.

How Smart Flow Engineering Supports Factory Automation Reliability

At Smart Flow Engineering, we support industrial businesses with automation, electrical and engineering services designed to help maintain reliable operations.

Our service capabilities cover several important areas of industrial automation:

Automation & Control Systems

PLC upgrades and migration, HMI maintenance, control panel modifications, industrial network upgrades and obsolescence assessments.

Drives & Motion

Industrial drive assessment, AC/DC drive servicing, replacement, retrofits and commissioning of drive systems.

Electrical & MEICA

Industrial electrical installation, control panel wiring, equipment integration and electrical maintenance support.

Testing & Commissioning

Functional testing, I/O verification, fault finding, diagnostics and commissioning support.

Technical Support & Maintenance

Planned preventive maintenance, equipment inspections, software backups and reliability support.

Our approach is focused on helping businesses assess existing equipment, identify potential issues and plan appropriate maintenance or upgrades.

Whether you are experiencing recurring automation faults or looking to improve the condition of ageing equipment, a structured engineering assessment is a practical starting point.

Final Thoughts

Improving factory automation reliability requires a combination of preventive maintenance, effective fault diagnosis, electrical inspections and well-planned equipment upgrades.

Rather than reacting to breakdowns, manufacturers should take a proactive approach to understanding the condition of their automation systems and addressing potential risks before they affect production.

Regular assessments, accurate documentation and appropriate engineering support can help improve equipment availability, reduce unexpected interruptions and support more reliable manufacturing operations.

Looking to improve the reliability of your factory automation systems?

Contact Smart Flow Engineering to discuss your automation, drives, electrical and maintenance requirements.

Website: https://smartfloweng.com

Telephone: +44 1234 440 530

Frequently Asked Questions

1. What is factory automation reliability?

Factory automation reliability is the ability of automated machinery, control systems and electrical equipment to operate consistently with minimal unexpected failures or production interruptions.

2. How can manufacturers improve factory automation reliability?

Manufacturers can improve reliability through preventive maintenance, regular electrical inspections, PLC and HMI upgrades, drive servicing, software backups and structured fault diagnosis.

3. Why is preventive maintenance important in automated factories?

Preventive maintenance helps identify equipment deterioration and potential faults before they develop into major failures. It also supports better maintenance planning and reduces the likelihood of unexpected production interruptions.

4. How often should industrial automation systems be inspected?

Inspection frequency depends on equipment criticality, operating conditions, manufacturer recommendations and site maintenance requirements. Critical equipment may require more frequent checks than non-essential machinery.

5. What causes industrial automation systems to fail?

Common causes include electrical faults, overheating, component wear, outdated PLC hardware, communication failures, poor maintenance and incorrect equipment configurations.

6. When should a factory upgrade its PLC or control system?

A PLC or control system upgrade should be considered when hardware becomes obsolete, spare parts are difficult to source, technical support is limited or recurring faults affect production reliability.

7. What is an industrial automation health check?

An industrial automation health check is a structured assessment of equipment such as PLCs, HMIs, industrial drives, electrical panels and control systems to identify potential risks and maintenance or upgrade requirements.

8. Can upgrading industrial drives improve equipment reliability?

Yes. Replacing or retrofitting ageing or unsupported drives can help address component obsolescence and recurring equipment issues, provided the replacement is correctly selected, integrated and commissioned.