Manufacturers must ensure that the machines inside the facilities are always in good working condition to avoid production stoppage. One way to do this is to inspect all plant equipment and fix all detected problems before they worsen. Machines need proper maintenance to prevent breakdowns and prolong their lifecycle.
Some companies let their industrial equipment operate at maximum capacity and wait until it malfunctions before it is time for repair. However, other businesses opt to take necessary manufacturing preventive maintenance before the machines fail and stop working. According to 2020 statistics, 60% of companies connect preventive maintenance with better productivity, and over 60% with reduced downtime and enhanced safety. As many businesses recognize the importance of manufacturing preventive maintenance, it pays to be knowledgeable about keeping the machinery in safe, operable condition this 2024. Here’s a guide to help you.
Guide to Preventive Maintenance in Manufacturing
What is Preventive Maintenance?
Preventive maintenance, also known as Preventative Maintenance, aims to fix the plant equipment and prevent damages before they happen. A schedule is set in advance to conduct routine inspections, and maintenance, and perform necessary replacements or repairs. Manufacturing preventive maintenance minimizes the possibility of unforeseen issues. It recognizes the importance of identifying and preventing problems rather than reacting to them only when they already occur.
Difference between Reactive vs. Preventive Maintenance
Manufacturers must understand the difference between reactive and preventive maintenance to see the better choice for their facilities.
- Reactive maintenance addresses a machinery problem only when it has already broken down or malfunctioned. A maintenance technician identifies what went wrong and takes the necessary steps to restore and fix the machine into operational condition.
- Preventive maintenance sets regularly scheduled maintenance works to take care of the equipment. This reduces the chance of breakdowns that can lead to unscheduled downtime and costly repairs or replacements.
There are different types of preventive maintenance strategies that manufacturers can use for their industrial equipment.
Types of Manufacturing Preventive Maintenance
1. Time-Based Maintenance
It is also known as “calendar-based” maintenance. This approach focuses on setting up a rigid schedule with intervals for manufacturing preventive maintenance activities. This time-based measure conducts regular inspections on machines, especially those that would create a huge impact on production when they suddenly break down.
2. Usage-Based Maintenance
This type of manufacturing preventive maintenance is performed after a certain amount of runtime. This happens as often as equipment requires maintenance, whether it is every month or every six months.
3. Condition-Based Maintenance
Machine parts are replaced immediately when they appear like they are getting excessively worn out from prolonged use so they can continue to work properly.
4. Predictive Maintenance
Historical data are used to predict when mechanical parts will break and replace them before they get damaged. This typically uses artificial intelligence and machine learning.
5. Prescriptive Maintenance
This advanced data analysis method gives hypothetical results so manufacturers can select the best option to take before a machine fails.
Manufacturing preventive maintenance aims to extend the lifespan and increase the productivity of industrial equipment as well as to keep the safety of people and machines. Manufacturers can achieve several advantages from a properly-implemented preventive maintenance program, such as the following:
5 Benefits of Manufacturing Preventive Maintenance
1. Ensures the safety of machine users.
Replacing machine parts before they malfunction and cause damage to other parts makes the equipment safe to use for operators and technicians.
2. Enhances the quality of products.
Manufacturing preventive maintenance such as changing a machine part before it gets worn out can lead to improved quality of finished goods that are produced in large amount.
3. Minimizes downtime due to broken machine parts.
Breakdowns can lead to extended downtime, especially if the problematic parts are fused with other parts of the machine. Through manufacturing preventive maintenance, replacing broken parts is faster to accomplish since the upkeep is scheduled in advance.
4. Saves money.
Replacing equipment parts before they break down can save money because there is less chance that surrounding parts are also damaged.
5. Extends the lifecycle of a machine.
The lifespan of a machine can be extended for several years or even decades when a proper manufacturing preventive maintenance plan is in place.
Preventive maintenance involves four fundamental actions. Here is a closer look at how each of them is essential to a successful manufacturing preventive maintenance program.
4 Vital Actions in Preventive Maintenance
1. Inspection
Regular inspections are important in manufacturing preventive maintenance because they ensure that equipment is safe to use and function properly. They avoid workplace injuries and protect the property.
2. Detection
Preventive maintenance can help facility managers detect issues in advance, making it easy and inexpensive to fix the problems.
3. Correction
Through manufacturing preventive maintenance, problems (or possible issues) are address immediately. Once detected, facility managers can take necessary steps to correct the problems before they worsen or stop the operations.
4. Prevention
Inspection records and maintenance notes are collected to learn about the failure history of a machine. Doing this makes it easier to know the previous mistakes and correct repeated issues. Breakdown prevention helps minimize stress and increases the productivity of workers.
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Manufacturers can use preventive maintenance to ensure that all machines are working in perfect condition. Identifying and fixing the issues before they occur can avoid sudden breakdowns that cause downtime and delays at work. This also prevents staff from suffering injuries if they continue working on dangerous machinery. Manufacturing preventive maintenance is more inexpensive than fixing industrial equipment that breaks down in the middle of an operation.
Elixir is a reliable industrial equipment supplier in the Philippines that also offers Aftersales Support, Spare Parts, and Maintenance services to its customers after the purchase has been made. The support services include fast response time, on-call machine diagnosis and action plan recommendation, machine annual maintenance, and line audit maintenance. Do you need a machine supplier that also provides maintenance services for your business? Elixir can assist you.