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There is nothing quite as expensive as silence on a factory floor. When the sound of production comes to a grinding halt because of some unforeseen failure, the costs quickly add up. You lose money on products that don’t get made, you lose money on workers who don’t get to work, and you lose money on repairs, which, quite often, can be quite exorbitant. When it comes to any organization that uses machinery, the ultimate goal is to have that machinery running as efficiently and for as long a time as possible.
The longevity of any operation is not dependent on chance, but on a commitment to its care. While it is impossible to prevent wear and tear, it is possible to prevent many of the disasters that cause that machinery to fail. By making a change in your mindset that gets you away from reactive maintenance and towards a more preventative approach, you can extend the longevity of your operation. Here are five essential strategies that will help you keep your operation running smoothly.
1. Training Your Operators Thoroughly
The most advanced machine on any factory floor is often the operator that stands in front of that machine. Your entire maintenance strategy should begin with operator training. An operator who is well-trained on the intricacies of that machine is your first line of defense against failure. This means that they must be able to identify the early warning signs that a failure is about to happen.
In addition, operators must also be well-trained on how to properly shut down a machine that is failing. When a machine fails, an operator who knows how to properly shut down that machine could be the difference between a minor repair and a complete replacement.
2. Keep it Clean and Debris-Free
It may sound too simplistic, but cleanliness is an important factor in the overall well-being of the machine. The work environment is always dirty, with lots of dust. However, it is important to ensure that the machine is clean. If you fail to clean it, it is a recipe for disaster. The grime that accumulates on the machine can act as an insulator. This can cause an engine or motor to overheat.
It is also important to maintain a cleaning schedule. This will enable you to check the overall physical condition of the machine. This is also an important time to check specific issues with the machine. For example, if you notice an issue with the motor, it is important to get hydraulic motor repair in Houston instead of waiting until the machine loses all function.
3. Stick to a Lubrication Schedule
One of the biggest enemies of machine well-being is friction. Without enough oil, the machine will rub against itself, causing the different parts to overheat. This will cause them to degrade faster than they should. However, it is not just about applying oil on occasion. There should be a schedule that explains which oil to apply to which machine.
It is also important to note that too much oil can cause more harm than good. Some manufacturers offer specific information on the viscosity of the oil. Sticking to this will ensure smooth bearings and gears.
4. Monitor for Signs of Distress
Machines will not break down without first giving some kind of warning – they will often “broadcast” their problems well in advance, if you are listening. Part of any regular inspection should be to listen for changes in the machine’s behavior. There are two primary warnings that something is wrong with the machine: vibration and temperature.
Excessive machine vibration can often be an indication of machine problems, such as machine misalignment, imbalance, or looseness in the mounting. Excessive temperature can be an indication of friction problems, etc. By incorporating thermal imaging or vibration analysis into your inspection process, you will be able to detect hidden problems early on.
5. Maintain a Critical Spares Inventory
Even with the best of maintenance practices, machine parts will still fail. When they do, the amount of time that your business will be idle depends on the inventory that you have on site. Waiting weeks for a specific bearing or motor to ship in from overseas is not necessary.
Analyze your machine to determine critical spares that have either a long lead time to acquire, or which have high failure rates. Having these critical spares on site will prevent unexpected downtime. Having the part on the shelf means that what could have taken weeks to acquire will only take a few minutes in the morning to get the machine running again. Even if it’s not a repair you can do yourself, you can still have the number of a reliable repair company saved and ready to go.
Prioritize Proactive Care
The difference between having a profitable quarter versus one that is struggling may depend on the reliability of the equipment. By prioritizing operator care, cleanliness, lubrication, inspection, and inventory, you will move away from the chaos of reactive maintenance. By going proactive, you will ensure that your machine runs smoothly, and your production line will be busy!
