Repair Urgency Simulator | Master Reliability 2/2

Roller

Rotating element in conveyor

Component Name	OperatorTip	Diagnostic Cell	Out-of-control Detection	Criticality
Roller				Medium
Idler				Low
Workholding device				High
Tooling				High
Fixture				Medium
Jig				Medium
Cutting tool				High
Grinding wheel				High
Welded torch				High
Welding wire				Medium
Electrode				Medium
Paint sprayer				Medium
Robotic arm				High
End effector				High
Safety guard				High
Light curtain				High
Emergency stop button				High
Interlock				High
Alarm				Medium
Indicator				Medium
Labeling system				Medium
Barcode scanner				Medium
Vision system				High
Calibration tool				Medium
Measuring instrument				Medium
Micrometer				Medium
Caliper				Medium
Dial indicator				Medium
Pressure gauge				Medium
Thermometer				Medium
Data logger				Medium
Controller				High
Software interface				High
Industrial PC				High
Networking switch				High
Router				High
Antenna				Medium
Power distribution unit				High
Battery backup				High
Surge protector				Medium
Grounding system				High
Static eliminator				Medium
Environmental monitor				Medium
Cleanroom component				High
Packaging materials				Low
Pallet				Low
Bin				Low
Tote				Low
Measuring handling equipment				High
Hoist				High
HVAC unit				High
Dust collector				Medium

Component Name	Proper Care	Automated Care and Detection	FailPreventionGen	Common Failures
Roller				Bearing wear, misalignment
Idler				Wear, misalignment
Workholding device				Loosening, misalignment, wear
Tooling				Wear, breakage, misfit
Fixture				Wear, misalignment, fatigue
Jig				Wear, deformation
Cutting tool				Dulling, chipping, breakage
Grinding wheel				Cracking, imbalance, wear
Welded torch				Clogging, overheating, nozzle damage
Welding wire				Contamination, feed issues
Electrode				Moisture absorption, breakage
Paint sprayer				Clogging, uneven spray, pressure loss
Robotic arm				Joint wear, encoder failure, control faults
End effector				Loosening, misalignment, wear
Safety guard				Loosening, damage, misalignment
Light curtain				Lens contamination, misalignment
Emergency stop button				Contact wear, mechanical failure
Interlock				Misalignment, sensor failure
Alarm				Bulb failure, wiring fault
Indicator				LED failure, wiring issues
Labeling system				Misfeed, print errors, adhesive failure
Barcode scanner				Lens damage, misalignment, software error
Vision system				Lens contamination, lighting issues
Calibration tool				Wear, misalignment, contamination
Measuring instrument				Wear, misalignment, zeroing error
Micrometer				Jaw wear, scale drift
Caliper				Scale drift, jaw misalignment
Dial indicator				Gear wear, needle sticking
Pressure gauge				Diaphragm rupture, clogging
Thermometer				Drift, sensor damage
Data logger				Memory failure, sensor dropout
Controller				Software bugs, I/O failure
Software interface				UI bugs, data loss, lag
Industrial PC				Overheating, disk failure, EMI issues
Networking switch				Port failure, overheating, firmware bugs
Router				Configuration errors, signal loss
Antenna				Signal degradation, physical damage
Power distribution unit				Overload, breaker failure, loose wiring
Battery backup				Battery degradation, inverter failure
Surge protector				MOV failure, loose connections
Grounding system				Loose connections, corrosion
Static eliminator				Wear, emitter failure
Environmental monitor				Sensor drift, data loss
Cleanroom component				Seal failure, material degradation
Packaging materials				Tearing, contamination
Pallet				Cracking, warping
Bin				Cracking, contamination
Tote				Handle damage, cracking
Measuring handling equipment				Motor failure, structural damage
Hoist				Cable wear, brake failure
HVAC unit				Compressor failure, sensor drift
Dust collector				Filter clogging, motor failure