When it comes to machine maintenance, there are a lot of details to consider, and there is a matter that every production company must face.
There are several types of machine maintenance, but three of them are the most common. These are preventive, predictive, and corrective maintenance. In this article we are going to take a closer look at each one of them, but let’s start with the basics.
What is machine maintenance?
Machine maintenance is, simply put, the process of keeping machines in good working condition. It involves performing regular tasks to inspect, clean, lubricate, and repair machines. It refers to the regular servicing and care of machinery and equipment to keep it operating safely and efficiently.
Effective machine maintenance is important for preventing failures, extending the life of machines, and improving safety. It keeps production assets in optimal operating condition to achieve reliability, quality, and safety goals. Some key points about machine maintenance:
- It aims to minimize downtime and maximize lifespan of equipment
- Data-driven machine maintenance strategies are increasingly used based on predictive analytics
- It is critical for industrial facilities, factories, plants to maintain production
- Compliance with safety regulations is a key focus, identifying risks before incidents
- It should be performed only by skilled technicians, certified if possible
- Machine maintenance tasks can range from simple cleaning and lubrication to complex disassembly and overhaul
- It reduces costs associated with replacements and unplanned stoppages
- Documentation through computerized maintenance management systems is important
- It uses technologies like machine sensors, data analytics, and machine learning algorithms to detect subtle changes and trends in equipment operation
- It identifies developing problems like abnormal vibrations, temperature changes, lubricant breakdown, etc.
- It forecasts maintenance needs based on degradation indicators rather than fixed schedules
- The goal is to avoid unplanned reactive maintenance and do proactive maintenance just before failure
Machine maintenance can be performed by in-house personnel or by outsourced maintenance providers. The best option for a particular organization will depend on a variety of factors, such as the size and complexity of the organization’s equipment, the budget, and the availability of skilled maintenance personnel.
Predictive maintenance
Machine predictive maintenance is the use of data and analytics to predict when equipment is likely to fail. This allows for repairs to be scheduled before a failure occurs, minimizing downtime and costs. Predictive maintenance can be performed using a variety of methods, such as vibration monitoring, oil analysis, and infrared thermography.
Predictive maintenance is a valuable tool for organizations of all sizes. It can help to reduce downtime, extend the life of equipment, and improve safety. It is also a key component of Industry 4.0, which is the fourth industrial revolution that is characterized by the use of big data, artificial intelligence, and the Internet of Things (IoT).
Advantages of predictive maintenance
Here are some of the benefits of machine predictive maintenance:
Reduced downtime: By predicting when equipment is likely to fail, predictive maintenance can help to reduce downtime and improve productivity.
Extended machine life: Predictive maintenance can help to extend the life of machines by preventing wear and tear. This can save money on replacement costs.
Improved safety: Predictive maintenance can help to improve safety by ensuring that machines are in good working condition. This can help to prevent accidents and injuries.
Reduced maintenance costs: Predictive maintenance can help to reduce maintenance costs by avoiding unnecessary repairs and by extending the time between scheduled maintenance tasks.
Improved energy efficiency: Predictive maintenance can help to improve energy efficiency by ensuring that machines are operating at their optimal performance.
How to implement predictive maintenance
Predictive maintenance can be implemented in a variety of ways. One common approach is to use sensors to collect data on the condition of equipment. This data can then be analyzed using machine learning algorithms to predict when equipment is likely to fail. Another approach is to use historical data on equipment failures to develop predictive models.
Even though predictive maintenance is a complex technology, it is becoming more and more popular. As the cost of sensors and machine learning algorithms continues to decrease, predictive maintenance is becoming more affordable and accessible to organizations of all sizes.
Examples of predictive maintenance
Here are some examples of how machine predictive maintenance is used in different industries:
Manufacturing: It is used to monitor the condition of equipment in manufacturing plants, such as robots, CNC machines, and assembly lines. This helps to prevent equipment failures that can disrupt production and lead to lost revenue.
Transportation: It is used to monitor the condition of vehicles in transportation fleets, such as trucks, buses, and trains. This helps to prevent breakdowns on the road that can lead to delays and safety hazards.
Energy: It is used to monitor the condition of equipment in power plants and other energy facilities. This helps to prevent equipment failures that can lead to power outages and other disruptions.
Healthcare: It is used to monitor the condition of medical equipment, such as MRI machines, X-ray machines, and patient monitors. This helps to prevent equipment failures that can delay or cancel patient procedures.
Machine predictive maintenance is a powerful tool that can help organizations to improve their operations and reduce costs. As technology continues to develop and become more affordable, it is likely to be adopted by even more organizations in the future.
Preventive maintenance
Machine preventive maintenance is the practice of performing regular maintenance tasks on machines to prevent failures from occurring. This can include tasks such as lubricating bearings, changing filters, and inspecting for signs of wear and tear. Preventive maintenance is typically performed on a schedule, such as once a month or once a year.
The goal of preventive maintenance is to extend the life of machines and reduce downtime. By identifying and fixing potential problems before they cause a failure, preventive maintenance can save organizations money in the long run.
Advantages of preventive maintenance
Here are some of the benefits of machine preventive maintenance:
Reduced downtime: By preventing equipment failures, preventive maintenance can reduce downtime and improve productivity.
Extended machine life: Preventive maintenance helps to extend the life of machines by preventing wear and tear. This can save money on replacement costs.
Improved safety: Preventive maintenance helps to improve safety by ensuring that machines are in good working condition. This can help to prevent accidents and injuries.
Reduced maintenance costs: Preventive maintenance can help to reduce maintenance costs by avoiding unnecessary repairs and by extending the time between scheduled maintenance tasks.
Improved energy efficiency: Preventive maintenance can help to improve energy efficiency by ensuring that machines are operating at their optimal performance.
How to implement preventive maintenance
Preventive maintenance can be performed by in-house personnel or by outsourced maintenance providers. The best option for a particular organization will depend on a variety of factors, such as the size and complexity of the organization’s equipment, the budget, and the availability of skilled maintenance personnel.
Tasks as simple as a visual inspection or as complex as a complete overhaul of a machine can be part of a preventive maintenance plan. The specific tasks that need to be performed will depend on the type of welding equipment and its operating environment. For example, welding machines that are used in a dusty environment may require more frequent filter changes.
It is important to note that preventive maintenance is not a guarantee against equipment failure. However, by performing regular preventive maintenance tasks, organizations can significantly reduce the risk of equipment failures and minimize the impact of failures that do occur.
Examples of preventive maintenance
Here are some examples of how machine preventive maintenance is used in different industries:
Manufacturing: The tasks may include inspecting and lubricating machinery, changing oil and filters, and cleaning and repairing equipment.
Transportation: Inspecting and lubricating vehicles, changing tires and brakes, and servicing engines, are part of the task in this segment.
Healthcare: It includes inspecting and calibrating medical equipment, cleaning and disinfecting equipment, and changing filters.
Construction: It involves inspecting and lubricating heavy equipment, changing blades and other attachments, and servicing engines.
Energy: The tasks may include inspecting and cleaning power plant equipment, changing filters, and servicing engines.
Food and beverage: The cleaning and sanitizing of processing equipment, inspecting and lubricating equipment, and changing filters are part of the tasks to be performed.
Hospitality: Preventive maintenance tasks in hospitality may include inspecting and cleaning hotel rooms and other facilities, servicing HVAC equipment, and changing air filters.
Example of a predictive and preventive maintenance program
Let’s see now an example of a predictive and preventive maintenance program for the welding and cutting equipment of a metalworking company that manufactures metal furniture
- Identify the welding equipment that needs to be covered by the program. This will include all the welding and cutting machines, wire feeders, and other accessories that are used in the manufacturing process
- Assess the risk of failure for each piece of equipment. This can be done by considering factors such as the age of the equipment, the frequency of use, and the operating environment
- Develop a maintenance schedule for each piece of equipment. This schedule should be based on the risk of failure and the manufacturer’s recommendations
- Implement the maintenance schedule. This can be done in-house or by outsourcing to a maintenance provider
- Monitor and adjust. Monitor the condition of the equipment and adjust the maintenance schedule as needed
Here are some specific examples of predictive and preventive maintenance tasks that can be performed on welding and cutting equipment.
Activities for predictive maintenance tasks
- Install vibration sensors on welding machines to monitor for abnormal vibration patterns indicating imminent failures. Track trends
- Use thermal cameras to scan welder equipment and connections for hot spots that could denote issues like loose connections or friction
- Monitor power quality metrics for spikes and anomalies that stress welders
- Periodically take weld quality measurements and track over time. Detect declines indicating need for adjustments
- Log runtime hours on welding machines and plan maintenance accordingly
Activities for preventive maintenance tasks
The following can be daily maintenance activities
- Quick visual/audio check for obvious issues
- Clean spatter and debris from fixtures
The following can be weekly maintenance activities
- Clean air filters if present
- Inspect welding tips/nozzles and replace as needed
- Verify calibrated settings on equipment
The following can be monthly maintenance activities
- Thorough cleaning of parts and wigglers
- Inspect all cables and hoses for damage
- Test cooling system water quality
The following can be quarterly maintenance activities
- Check all connections and bus links for tightness
- Lubricate moving parts like carriage wheels
- Verify calibration with test welds
The following can be yearly maintenance activities
- Complete disassembly and overhaul of cooling pumps, torches, and internal components
- Calibrate sensors, meters, gauges
- Document all maintenance tasks, findings, parts installed and measurements. Continually optimize based on review of predictive data and failure rates
Corrective maintenance
Machine corrective maintenance is the repair of equipment after it has failed. This type of maintenance is typically more expensive and disruptive than preventive maintenance, as it often requires downtime to repair the equipment. Corrective maintenance should be avoided whenever possible, but it is necessary in some cases.
Corrective maintenance is an important part of any organization’s maintenance strategy. However, it is important to note that it is not a substitute for preventive maintenance. Preventive maintenance is the best way to reduce the risk of equipment failures and minimize the impact of failures that do occur.
Key aspects of corrective maintenance
We do not want to sound alarmists, but it is never good news when some equipment fails and needs urgent corrective maintenance. Key aspects of corrective maintenance include:
- The main goal is to fix actual equipment failures causing stoppages and restore operating status
- Actions are taken after the equipment has already failed, in reaction to the problem, so it is reactive in nature
- Troubleshooting is needed to diagnose root cause of failure based on symptoms
- Often requires disassembly to access and remove broken components
- Requires parts and tools for repair work. Inventory management is important
- Focus is on swift repairs to minimize downtime
- The aim is to get the equipment back to its pre-failure state
- Temporary fixes may be needed before full repair is completed
- Documentation of work details and parts are critical for tracking
- Personnel need broad diagnostic and repair competency.
How to implement corrective maintenance
Corrective maintenance can be performed by in-house personnel or by outsourced maintenance providers. The best option for a particular organization will depend on a variety of factors, such as the size and complexity of the organization’s equipment, the budget, and the availability of skilled maintenance personnel.
This can be a complex and time-consuming process. It is important to properly diagnose the problem before attempting to repair the equipment. This may require specialized knowledge and skills.
It is also important to use the correct parts and tools when performing corrective maintenance. Failure to do so could result in further damage to the equipment or even lead to safety hazards.
Once the repair is complete, it is important to test the equipment to ensure that it is working properly. This may involve running the equipment through a series of tests or simply observing it in operation.
How to minimize the need for corrective maintenance
Here are some tips for minimizing the need for corrective maintenance. By following these tips, you can help to extend the life of your equipment and reduce the need for corrective maintenance.
- Perform regular preventive maintenance tasks
- Monitor the condition of your equipment for signs of wear and tear (predictive maintenance)
- Use the equipment properly
- Avoid overloading the equipment
- Have the equipment inspected and serviced by a qualified technician on a regular basis.
Why is machine maintenance important?
Here are some of the benefits of regular machine maintenance (preventive and predictive):
Reduced downtime: Machine maintenance helps to prevent equipment failures, which can reduce downtime and improve productivity.
Extended machine life: Machine maintenance helps to extend the life of machines by preventing wear and tear. This can save money on replacement costs.
Improved safety: Machine maintenance helps to improve safety by ensuring that machines are in good working condition. This can help to prevent accidents and injuries.
Increased efficiency: Machine maintenance can help to improve the efficiency of machines by ensuring that they are operating properly. This can lead to reduced energy costs and improved product quality.
How to apply machine maintenance in your plant?
Which type of maintenance is best for a particular asset will depend on a variety of factors, such as the cost of downtime, the criticality of the asset, and the risk of failure. In general, it is best to use a combination of predictive, preventive, and corrective maintenance to achieve the most cost-effective and reliable maintenance strategy.
It is also important to note that predictive and preventive maintenance programs are not a one-size-fits-all solution. The best program for a particular company will depend on the size and complexity of the company’s welding equipment fleet, the budget, and the availability of skilled maintenance personnel.
Tips to apply machine maintenance in the production plant
Here are some additional tips for developing and implementing a successful predictive and preventive maintenance program for welding equipment:
- Use a computerized maintenance management system (CMMS) to track maintenance schedules and tasks
- Train maintenance personnel on the specific predictive and preventive maintenance tasks that need to be performed
- Use only high-quality replacement parts and tools
- Test the equipment after maintenance is complete to ensure that it is working properly.
Last thoughts
Follow the tips found in this article to establish your own predictive and preventive maintenance programs and get possible solutions on hand whenever you need to run corrective maintenance. By following these tips, you can help to extend the life of your welding equipment, reduce downtime, and improve safety.
As a summary, machine maintenance is an important part of any organization’s production strategy. By performing regular machine maintenance, organizations can reduce downtime, extend the life of their machines, improve safety, and increase efficiency.
