01 / INTAKE
Failure Definition
OEM, model, part number, photos, process conditions and urgency level.
SBS Industrial Solutions is based in Beylikdüzü, Istanbul and focuses on reducing unplanned downtime, rapidly assessing critical equipment problems and helping production return to service.
With 25 years of machinery, maintenance and field experience, we provide on-site surveys, fault diagnostics, MRO, reverse engineering, critical spare parts, express courier support, technical field inspections, OEM field support, filtration and treatment solutions. From Turkey, we aim to provide rapid technical support to Europe, the Middle East and international industrial markets.
Sometimes one right idea can prevent a $1 million loss.
To reduce unplanned downtime and total maintenance cost through accurate diagnosis, sound engineering and rapid response.
To question the true cause of failure before replacing a part, and whenever practical, evaluate repair, improvement, retrofit or remanufacturing alternatives.
Regional technical support for Europe, the Middle East, GCC countries and international manufacturers through a fast field-service organization based in Turkey.
SBS Industrial Solutions is an engineering-led MRO model built around equipment reliability, life extension, recovery of obsolete components and reduction of unplanned downtime. For eligible emergency cases, this is supported by a rapid-response service model.
When original drawings are unavailable, we reconstruct dimensions, identify materials, create CAD models and develop manufacturing plans from worn, damaged or legacy samples.
Critical component support for process pumps, reciprocating compressors, mechanical seals, couplings and selected rotating-equipment internals.
Low-volume CNC, EDM, grinding, lapping and qualified special processes for emergency and legacy-equipment requirements.
Repair, exchange and retrofit support for obsolete PLC, I/O, VFD and industrial control hardware.
Approved dimensions, material data, manufacturing routes and quality records retained for faster future reproduction.
Priority is given to assets where long OEM lead times, obsolescence or low availability can materially affect production.
The 72-hour target applies only where engineering, material, safety, certification and manufacturing conditions allow. Every case is technically screened before commitment.
OEM, model, part number, photos, process conditions and urgency level.
3D scanning, CMM inspection, material verification, CAD and tolerance review.
Repair, machining, EDM, grinding, rebuild, retrofit or an approved replacement solution.
Dimensional quality control, functional verification and supporting documentation where applicable.
Expedited packing, air freight and site coordination to support return to service.
SBS Industrial Solutions provides independent technical support for high-speed production machinery, process equipment, rotating equipment, automation systems and hard-to-source critical components.
Technical identification, reverse engineering, manufacturing and express delivery for obsolete, long-lead or unavailable components.
Dismantling, installation, mechanical execution, commissioning, testing and technical field coordination for industrial production machinery.
For critical parts, standard logistics may be too slow. Where practical, we use dedicated courier, same-day air freight and Hand-Carry / On-Board Courier options to accelerate direct delivery to site.
SBS Industrial Solutions’s approach is based on knowledge and field practice gained over 25 years in machinery and industrial service. The objective is to reduce unplanned downtime, unnecessary part replacement, international service travel and the total cost of recurring failures.
The right material choice, tolerance correction, small mechanical modification, process parameter adjustment, sensor positioning or elimination of the true root cause can prevent expensive equipment replacement and prolonged downtime. Our goal is not only to fix the failure, but also to identify improvements that can help prevent recurrence.
In industry, the most expensive element is often not the part itself; it is the time the machine remains out of service. That is why accurate fault diagnostics, fast field response, avoiding unnecessary replacement of repairable parts and using the right logistics model for critical components can have a direct impact on total cost.
A wrong diagnosis does more than create unnecessary spare-part cost; it also extends downtime. Survey, measurement and systematic fault diagnostics are the first steps.
Where technically and safely appropriate, repair, rebuild or remanufacturing can offer a significant cost advantage over complete equipment replacement.
With local survey and technical reporting, an OEM engineer can arrive with the right parts, the right tools and a clearly defined scope when specialist intervention is truly required.
For suitable components, reverse engineering, retrofit or technically validated alternatives can extend the economic life of equipment.
Identifying components that can stop production and defining a critical-spares strategy in advance can significantly reduce waiting time.
For urgent cases, Hand-Carry, dedicated courier and priority air-freight options are evaluated to minimize time to site.
Instead of repeatedly repairing the same failure, we analyze its root cause. We evaluate operating conditions, alignment, lubrication, vibration, temperature, automation, process and design factors together to develop practical engineering solutions for recurring problems. Our objective is not only to restore operation, but also to reduce recurrence, improve equipment reliability and help prevent unplanned downtime.
Part cost, labor, travel, logistics and production loss should be evaluated together. The lowest purchase price is not always the lowest total cost.
A key lesson from 25 years in the field is that major industrial losses are not always caused by major equipment. A small sensor, incorrect tolerance, inadequate lubrication, misalignment or a minor mechanical deviation can stop an entire production line.
Incorrect sensor positioning or an unstable signal can repeatedly trigger safety stops. Correcting mounting position, wiring or sensing conditions may solve the issue without replacing the sensor.
A small tolerance error in a shaft, sleeve, bearing arrangement or moving component can cause vibration, heat and premature wear. Accurate measurement and correction may avoid replacement of the complete unit.
Small pump or motor alignment deviations can damage multiple components over time. Correcting the alignment cause rather than only replacing damaged parts can reduce recurring maintenance cost.
Material that is unsuitable for temperature, chemical exposure or wear conditions can dramatically shorten component life. A targeted change in material or surface treatment can significantly extend service life.
Insufficient lubrication, contaminated oil, a blocked small passage or inadequate cooling can damage bearings and other precision components. Replacing parts without correcting the root cause can lead to repeated failure.
In some cases, the mechanical component is healthy while timing, drive parameters, limits or feedback issues cause abnormal machine behavior. Accurate diagnosis helps avoid unnecessary part replacement.
This figure is not a guarantee or a fixed calculation for every plant; it is an illustrative scenario. In a high-capacity facility, the cost of several hours or days of unplanned downtime can be hundreds or thousands of times higher than the value of the small component that caused the failure.
That is why SBS Industrial Solutions does not start with “Which part failed?” but with “Why did production stop, and how can we prevent it from happening again?”
One of the biggest costs in unplanned downtime is replacing parts before the failure source is confirmed, or sending the wrong specialist to site. SBS Industrial Solutions performs on-site surveys and diagnostics to systematically assess whether the problem is mechanical, electrical, automation-, process- or equipment-related.
The current condition of the machine and plant, failure history, operating conditions, access points, auxiliary systems and technical service requirements are reviewed on site.
Symptoms and available data are evaluated to narrow down possible failure sources. Where appropriate, mechanical, electrical and automation checks are used to assess root cause.
Photos, videos, part numbers, dimensions, alarm records, operating parameters and available technical documents are collected to build a field file for service or manufacturing decisions.
When needed, the manufacturer or specialist engineer can join remotely using live video and field data, allowing the scope and required equipment to be defined before international travel.
Based on the assessment, repair, part replacement, reverse engineering, remanufacturing, retrofit or OEM support options are evaluated and a recommended action plan is prepared.
Field findings, identified problems, photos, measurements, critical risks, recommended actions and required parts can be presented in a structured technical report to the customer or OEM.
Even if the machine brand or exact failure type is not yet clear, send us the available information. After an initial technical review, we can define the appropriate field team, measurement equipment and expertise required for the survey.
Fault diagnostics and root-cause analysis are performed within the limits of available field data and applicable tests. Some cases may require additional testing, dismantling, laboratory analysis or OEM support.
You do not need to fly your own specialist thousands of kilometers for every service case. SBS Industrial Solutions provides local technical representation, preliminary inspection, fault diagnostics, on-site survey, installation supervision and first response to help reduce service time and total field cost.
We can reach the site before the OEM engineer, inspect the equipment, collect photos, videos and measurements, validate the failure scope and provide the manufacturer with a structured technical report. Where appropriate, we can also support field work under remote OEM guidance.
Pre-service field inspection, customer coordination and technical data collection on behalf of the manufacturer.
Rapid local field response for suitable cases without waiting for international service personnel to travel.
A regional service model designed to reduce flights, accommodation, waiting time and long-distance service travel.
If the issue cannot be resolved locally, field data can help the OEM specialist arrive prepared with the correct parts, tools and work plan.
SBS Industrial Solutions does more than respond to failures. Within the agreed scope and capabilities, we perform preliminary technical inspections and condition assessments to provide manufacturers or buyers with field information that supports faster decision-making.
Preliminary assessment of machine condition, failure symptoms, site access, required equipment and potential spare-part needs.
Visual inspection, verification of available technical data, photo/video records and condition reporting against a defined checklist.
Local technical support using live video, field measurements and coordination to help the manufacturer assess the issue remotely.
Documentation of physical condition, equipment configuration and current operating condition for used industrial machinery, within the customer-defined scope.
On-site monitoring of installation progress, reporting of outstanding items and technical coordination between manufacturer and customer.
Structured field reporting with photos, videos, measurements, observations and action items to support faster decisions.
Note: Unless explicitly stated in the contract, SBS Industrial Solutions survey/inspection services do not replace accredited inspection bodies or statutory conformity certification. Scope is defined in advance for each equipment item and project.
Many failures in PLCs, HMIs, servo drives, VFDs, power supplies, I/O modules and industrial control boards can be evaluated through proper testing, measurement and component-level repair. Before replacing a complete unit, we assess whether repair or recovery is technically and economically viable.
When an OEM recommends replacing a complete PLC module, HMI or servo drive, total cost can become substantial. In some cases, however, the actual failure may be limited to the power stage, capacitors, IGBT/MOSFET devices, relays, optocouplers, drive circuitry, communication section, connectors, solder joints or other electronic components.
We first identify the actual failure. If repair is technically safe and economically justified, we evaluate intervention at the failed section or component level instead of replacing the complete unit.
Power supply, I/O channels, communications, relay/driver stages and damaged board components are evaluated. Component-level repair may be possible for suitable failures.
Power-up, display, touchscreen, backlight, power-supply and communication problems are inspected. Depending on model and failure condition, display, touchscreen or board-level repair may be possible.
DC bus, power stage, IGBT/MOSFET devices, driver circuitry, fans, capacitors, encoder feedback and control-board faults are tested to determine repair potential.
Electronic and functional checks are performed for overcurrent, under/overvoltage, output faults, communication problems and power-stage failures.
Burned or aged components, short circuits and power-supply issues are investigated in switched-mode power supplies (SMPS), industrial power supplies, control boards and special electronic modules.
For obsolete or difficult-to-source electronics, repair, replacement units, compatibility solutions or controlled modernization are evaluated on a project basis.
Alarm codes, machine behavior, burn marks, liquid exposure, overheating and previous interventions are reviewed.
Power rails, short circuits, power stages, driver circuits and related signal paths are checked with suitable test equipment.
When technically appropriate, failed components are replaced and solder joints, connectors and damaged PCB tracks are repaired in a controlled manner.
After repair, the unit is operated under available test conditions and power, output, communication and functions are verified.
Where access and authorization permit, existing parameters and configurations are preserved or backed up.
When required, we can support on-site installation, connection checks and controlled recommissioning of the repaired unit.
Note: Not every electronic failure is repairable. Safety-critical damage, processor/memory loss, inaccessible proprietary software, severe PCB damage or uneconomical repair may require replacement or modernization. Repair decisions are made after testing and technical assessment.
Repairing a critical electronic or mechanical component is only one stage of returning production to service. When a line is down, delivery time also affects total downtime cost. SBS Industrial Solutions evaluates dedicated courier, Hand-Carry / On-Board Courier and priority air-freight options to deliver critical parts to site as quickly and reliably as practical.
For a stopped plant, standard logistics may not be fast enough. Depending on route and flight availability, dedicated courier arrangements can be made for repaired PLCs, HMIs, servo drives, control boards or critical mechanical parts.
Once repair and testing are complete, same-day dispatch can be arranged when route and operating conditions allow.
Highly critical, transportable parts may be carried by dedicated courier, subject to flight and customs conditions.
Our objective is not merely airport delivery; for suitable projects, we coordinate logistics through to the customer’s site.
Industrial cost is not limited to new machinery investment. The right process setting, cycle-time optimization, bottleneck analysis, maintenance strategy, automation parameter or small mechanical improvement can sometimes deliver higher capacity, lower scrap and lower unit cost with existing machinery.
A plant’s theoretical capacity and actual production capacity are often very different. Micro-stops, long changeovers, unnecessary waiting, poor line synchronization, low OEE and incorrect process parameters can limit the potential of existing machinery.
Our first objective is not to sell new machinery, but to determine how much more performance can be extracted from the existing equipment.
We identify the machine, transfer point, operator action or process step that truly limits line capacity, so investment decisions are based on the real bottleneck.
Availability, Performance and Quality losses are analyzed to identify the sources of small but recurring production losses.
Mechanical movements, process times and automation timing are reviewed within safe operating limits to evaluate cycle-time improvement potential.
Increasing the speed of one machine alone does not guarantee higher line capacity. The interaction between machines, buffer zones and transfers is evaluated as a complete system.
Energy, labor, scrap, maintenance, consumables and downtime losses are evaluated together to identify actions that can reduce true unit production cost.
Before investing in new machinery, we assess whether existing servo systems, drives, controls, mechanical systems, transfer equipment or process conditions can be economically improved.
Even a small per-unit improvement in energy, raw material use or scrap can create a major annual impact at high production volumes. Likewise, a 5–10% capacity increase may delay the need for a new production line in some facilities.
In a process with high raw-material value, even a small quality improvement can create significant annual savings.
Producing more with the same shifts and machinery can delay new investment and reduce fixed cost per unit.
Proper management of compressors, pumps, heating, cooling and standby modes can reduce total plant energy consumption.
Every minute saved during product or format changeover becomes additional available production time on lines with frequent changeovers.
SBS Industrial Solutions provides field-focused consulting for new or relocated production lines, including startup planning, equipment coordination, commissioning, capacity ramp-up and production stabilization.
A line running mechanically does not necessarily mean it is producing stably at target quality and capacity. During commissioning and ramp-up, process parameters, equipment synchronization, operator practices, critical spares and performance records should be addressed together.
The objective is to move from “the machine runs” to “the line produces sustainably at target capacity.”
Field verification of mechanical, electrical, utility, safety, critical-spares and production-readiness conditions.
Sequential commissioning, test runs, process monitoring and technical coordination of issues that arise.
Systematic improvement from first production to target speed by tracking cycle performance, quality, scrap and downtime.
Technical support to prepare the site team for production, fault response and critical maintenance points.
After data analysis, field observation and technical survey, low-cost improvements, retrofit options, bottleneck removal and truly necessary new CAPEX items can be reported separately.
In industrial processes, water quality, oil cleanliness, particulate control and correct filtration affect not only product quality but also the service life of pumps, valves, heat exchangers, compressors and precision equipment. SBS Industrial Solutions provides project-based support from system assessment and filtration selection to retrofit and replacement-filter supply.
Evaluation of pretreatment, filtration and membrane-based solutions for process water, utility water and reuse applications.
Technical evaluation of reverse osmosis, membrane filtration, pretreatment and capacity, pressure, fouling or performance issues in existing systems.
Filtration solutions for particulate and contamination control, including cartridge, bag, basket and process filters.
Particle control, filter elements, bypass/offline filtration and cleanliness solutions for hydraulic and lubrication systems.
Solid-liquid separation, separator applications, filter housings and performance improvements based on process requirements.
Optimization of performance and operating cost through targeted improvements to filter housings, pumps, controls, membranes or process layout instead of replacing the complete system.
A fouled heat exchanger, contaminated hydraulic oil, inadequate pretreatment or an incorrectly selected filter element can cause production loss and equipment damage. A relatively small filtration improvement can sometimes prevent much larger maintenance and downtime costs.
For urgent cases, once production or repair is complete, dedicated courier, Hand-Carry / On-Board Courier and priority air-freight options are evaluated instead of waiting for standard shipping cycles. Our goal is to minimize elapsed time from workshop release to customer site.
SBS Industrial Solutions can provide local technical representation, first response, preliminary fault assessment, on-site survey, commissioning support and technical coordination for international machinery and equipment manufacturers across Turkey and the Middle East. Instead of sending an OEM specialist internationally for every service request, manufacturers can first receive verified field information, measurements, photos, videos and condition reports. When specialist intervention is required, the scope can be defined in advance so the right personnel arrive with the right equipment and spare parts. The objective is faster customer response, controlled service costs and stronger regional after-sales capability.
Large spare-parts inventories can protect production, but they also lock capital into components that may remain unused for years. SBS Industrial Solutions offers a different approach for selected critical items: rapid technical assessment, repair, reverse engineering, alternative sourcing and express delivery. The objective is to balance plant reliability with a more efficient spare-parts strategy.
Instead of purchasing every possible spare in advance, criticality analysis can separate “must-stock” items from parts that can be repaired, reproduced or sourced quickly when required.
When OEM lead times are long, rapid diagnosis, local engineering and express courier options can significantly reduce the time between failure identification and return to service.
For suitable PLCs, HMIs, servo drives, control boards and mechanical components, repair or component-level recovery may cost far less than replacing the complete assembly.
Reverse engineering, retrofit and technically validated alternatives can help extend the useful life of equipment when original parts are discontinued or difficult to obtain.
A sensor position, tolerance, alignment, material, lubrication point, cooling condition or automation parameter can sometimes be the real reason behind repeated failures.
For urgent cases, dedicated courier, Hand-Carry / On-Board Courier and priority air freight can be evaluated to move critical parts to site as quickly as practical.
The most economical strategy is rarely “stock everything” or “stock nothing.” We help identify which components should remain on site, which can be repaired, which can be reverse-engineered and which can be supplied through rapid-response logistics.
Less capital tied up • Faster recovery • Lower downtime exposure • Smarter maintenance planning
Share the OEM/model, part number, photos, available dimensions, operating conditions and required delivery window. Our technical team will rapidly assess recovery and manufacturing feasibility.