Unplanned downtime rarely happens without a warning. Training teams to recognise those signals helps trigger emergency support before the issue escalates into a full shutdown.

Temperature spikes are the easiest to spot. When bearings or gearboxes run hotter than their baseline, investigate immediately. Infrared inspections offer a quick, non-invasive check across multiple assets.

Persistent vibration changes are another red flag. Don’t ignore new harmonics or resonance. They often accompany looseness, imbalance or damaged rotating elements that can fail catastrophically.

Next, pay attention to lubrication quality. Darkened oil, metal contamination or unusual odours show that components are wearing faster than expected. Sample analysis provides precise insight into wear mechanisms.

Finally, empower operators to escalate unusual noises and visual defects without delay. A quick response from a breakdown specialist can stabilise the asset, protect safety and put a permanent fix in play.