Preventing the 11% Revenue Leak: How EMRO & Quality Standards Slash Unplanned Downtime

A 2023 Siemens report titled "The True Cost of Downtime" found that Fortune Global 500 industrial companies lost about 11% of their annual revenue to unplanned downtime that year. This loss surged from the ~$864 billion figure reported in 2019-20. For reliability and maintenance engineers in power generation, oil & gas, and chemical processing, the root cause might not be visible to the naked eye. It might be poor vibration control, electrical runout, or other quality oversights.

This is why quality systems matter more now than ever. I'm pleased to announce that HFW Industries has successfully recertified to ISO 9001:2015. View our new certificate here. In an era where downtime costs are skyrocketing, our rigorous quality management system (QMS) is the engine that ensures repeatability, traceability, and resilience.

But certification alone doesn't prevent failures. Precision does.

Take electrical mechanical runout (EMRO) testing as an example. Most shops measure mechanical runout—whether a shaft is round. We go further. For certain shafts, EMRO testing can be used to detect electrical property variations in rotating equipment that standard dial indicators miss entirely. These hidden imperfections cause vibration, premature wear, and unexpected failures months after a part goes back into service.

Why the ISO 9001:2015 Certification Matters at HFW

ISO 9001:2015 provides the framework that governs how work moves through HFW, from contract review and material traceability to inspection, documentation, and continuous improvement.

Our quality system is designed to:

• Ensure consistent execution across machining, thermal spraying, grinding, hardfacing, and assembly
• Maintain full traceability of materials, specifications, and inspection records
• Reduce variability that leads to vibration, premature wear, and unexpected failures
• Support long-term asset reliability in critical industrial environments

ISO certification validates our system, but the value is in how that system is applied every day on the shop floor.

Quality in Practice Across Critical Industries

Turbomachinery and Power Generation

For turbine and compressor shafts, HFW measures:

• Total Indicated Runout (TIR)
• Diameter and length tolerances
• Electrical mechanical runout when required

Measurements are performed using micrometers, snap gauges, precision indicators, and dedicated electronic and mechanical runout inspection systems.

Chemical Processing Equipment

For mixers, agitators, and other chemical processing components, HFW verifies:

• Diameters and concentricity
• Surface finish using profilometers
• Coating integrity and substrate condition

These factors directly affect seal life, corrosion resistance, and process stability.

Complex Housings and Detailed Components

For intricately detailed parts and housings, HFW uses Coordinate Measuring Machines (CMMs) to probe features and calculate geometry with high accuracy, ensuring proper fit, alignment, and repeatability.

A Quality System Built on Discipline and Traceability

Quality has been a core business philosophy at HFW throughout our 75-year history. Our system has enabled us to deliver on customer commitments in demanding industrial environments.

Key elements include:

• Inspection at each operation, not just final inspection
• Extensive job records documenting specifications, materials, work scope, and inspections
• Independent calibration of gauges to NIST 2540-1 and ISO-10012 standards
• Continuous improvement through 5S and lean practices

Our quality department monitors every job through each operation to ensure final products meet or exceed customer requirements.

Inspection Capabilities That Support Tight Tolerances

HFW maintains two temperature-controlled inspection labs and more than 800 calibrated gauges, enabling us to inspect every job we perform.

Inspection capabilities include:

• Outside and inside micrometers up to 48”
• Snap gauges, bore gauges, and height gauges
• Granite surface tables up to 72” × 96”
• Coordinate Measuring Systems
• Profilometers, hardness testers, and ultrasonic thickness testers
• Optical comparators, microscopes, and dial indicators to 0.00005” graduation
• Electronic and mechanical runout inspection systems

When quality matters, nothing is left to chance.

A Culture of Quality, Not a Checkbox

Since our earliest days, HFW has maintained an intense focus on exceptional quality. That culture is reinforced through training, inspection discipline, and accountability at every operation.

Our reputation with leading industrial operators is built on one principle: consistent, world-class quality when reliability matters most. ISO 9001:2015 recertification confirms that commitment, but the real proof is in the performance of the equipment we return to service. For example, our HFW 512 coating helped increased the lifespan of chemical processing rolls by 30x.

Contact HFW Industries for Turnkey After-Market Solutions

Need to discuss a component rebuild, coating application, or emergency repair? Let's talk. Connect with our engineering team today to get a customized solution for your needs, all backed by the HFW Quality Policy.

📞 Call us at (716) 875-3380
📧 Email: RFQ@hfwindustries.com

Additional Technical Resources for Reliability, Maintenance, and Planning Teams

Sign up for our newsletter and explore these resources from our Knowledge Base:

• How Does HFW Serve the Turbomachinery Industry? — Learn about HFW's one-source repair and manufacturing strategy for turbines, rotors, and other turbomachinery equipment
• How HFW Extends Equipment Life — Real-world example of innovation in action: 30x increase in service life for a chemical client
• Reducing Assembly Time by 75% at 1/3 the Cost — Learn how HFW's one-source strategy can streamline our customer's processes and rein in costs
• Overview of Thermal Spray Coatings: HVOF & Tungsten Carbide — Why these materials are key to high-performance surface protection
• Precision Grinding at HFW — A look inside our plant, detailing HFW's precision finishing capabilities and CNC grinding
• What are HFW's Hardfacing Capabilities? — Explore how HFW’s hardfacing expertise restores industrial equipment with proven weld procedures and precision inspection

FAQ About Our Quality Policy

What does ISO 9001:2015 certification mean for customers?

It confirms that HFW operates under a documented, audited quality management system focused on consistency, traceability, risk management, and continuous improvement.

How is HFW’s quality process different from other shops?

HFW inspects jobs at each operation, reducing the risk of compounded errors and hidden defects that can lead to downtime.

What is EMRO testing, and when is it used?

Electrical mechanical runout (EMRO) testing identifies electrical property variations in rotating shafts that can cause vibration and premature failure. It is commonly applied to compressor and turbine shafts in critical applications.

Does HFW inspect every job?

Yes. With temperature-controlled inspection labs and extensive quality assurance capabilities, HFW inspects every job we perform.