Pro Tip: Identify the root cause of a issue to avoid spending a significant amount of time and money on unnecessary repairs.

Over the past year, I encountered two situations that demonstrated why identifying a problem is so important.

At one bakery, a proofer was experiencing problems that were believed to be related to the main conveyor chains. During my inspection the previous year, I had already determined that the chains were in good shape and were not the cause of the problem. I was unable to identify the root cause during my short trip, which included inspections of other equipment.

However, I suggested finding it before unnecessarily replacing the chains.

The bakery consulted a company that sells proofer chains, and their recommendation was to replace them. The bakery subsequently spent a significant amount of money on new chains.

When I returned the following year, the same problem was happening. Further investigation revealed bent framing and misaligned sprockets as the actual cause. The chains had nothing to do with the problem, and the money spent replacing them had accomplished nothing. The actual solution was simpler and far less expensive.

At another bakery, I was brought in to inspect an oven where the plant was planning to replace the main conveyor chains. In this case, the chains were obviously damaged and did need to be replaced, but I also found the reason they had failed: excessive spacing between a sprocket and a stabilizer shoe.

If the bakery had simply purchased new chains as planned, the same condition would have remained, and the new chains would have soon suffered the same fate.

Fortunately, the root cause was identified before the replacement was made.

In both cases, the bakeries sought advice from companies that sell replacement chains. While those companies may have valuable expertise, their business is selling chains and not determining whether you need them. That's why an independent evaluation can be so valuable.

If someone can't clearly explain what failed, why it failed and how the failure occurred in a way that makes sense even to a non-mechanic, they may not have identified the root cause.

Before replacing an expensive component, ask one simple question: Why did it fail?

Hire a company that won’t just sell you parts and only tell what needs to be replaced. Hire someone to help determine the root cause, explain what caused the failure or wear and then help you correct the problem before you spend good money after bad.

Mitch Brixey is manager of inspection services at Brixey Engineering Inc. He inspects more than 100 bakery ovens every year, often finding issues that would otherwise cause dangerous and expensive problems.

You can connect with him on LinkedIn.