In today’s manufacturing landscape, electronic systems play a pivotal role in the efficient production of goods, from raw material handling to the final packaging stage. Over the past five decades, the integration of electronics has revolutionized manufacturing processes, making them more streamlined and cost-effective. In contrast to the high-maintenance reliance on relays and hydraulics in the past, electronic systems generally offer greater reliability and demand less attention. However, this shift has led to a reduction in maintenance staff in many facilities, resulting in inadequate upkeep of manufacturing equipment and the emergence of third-party repair services.
Through numerous visits to diverse manufacturing settings, we have encountered both exemplary operations and those in need of significant enhancements. A recurring issue we’ve identified in several companies is the absence of comprehensive documentation for their operational equipment. While some companies possess manuals, few are well-versed in proactive maintenance procedures recommended for their equipment.
Outlined below are four practical guidelines for effective preventive maintenance:
1. Documentation Centralization
Gather and store all equipment documentation in a readily accessible location for easy reference by relevant personnel.
2. Critical Spare Parts Inventory
Acquire critical spare parts essential for sustaining the manufacturing process. While stocking every part may not be feasible, focusing on components with known wear issues or frequent failures can significantly minimize downtime.
3. Motor Controls and Associated Spares
Systems comprising multiple motor controls often encounter recurring issues. Maintaining a supply of spare motor controls and associated motors can mitigate potential disruptions.
4. Firmware and Parameter Retrieval
Establish procedures to retrieve firmware and parameter settings if not provided by the original equipment manufacturer (OEM) upon purchase. This practice ensures prolonged system operation and safeguards against potential OEM discontinuation.
While preventive maintenance does not guarantee complete issue prevention, adhering to these guidelines increases the likelihood of swift and effective restoration when issues arise. By proactively implementing these measures, manufacturing facilities can bolster operational resilience and longevity.
