Your high-speed machinery is at risk of breaking down. What can you do to prevent it?

Predictive maintenance needs to be adopted. A constant check on the behaviour of the moving components will help. This can be measurement of wear, operating temperature w.r.t specifications.We can also monitor chemical and environmental parameters as well if they affect the equipment. A sample check of presence of contaminants in the lubricating media will also help. Performance history of similar machines will help, if available. It is always a good practice to create a dossier of the maintenance and life of moving components.

Maintenance of equipment is of paramount importance in preventing downtime and ensuring the smooth operation of various industrial processes and systems. Neglecting regular maintenance can lead to a cascade of issues, including unexpected breakdowns, costly repairs, and production delays. By implementing a proactive maintenance strategy, organizations can significantly reduce the risk of equipment failure. Regular inspections, servicing, and repairs help identify potential issues before they escalate, allowing for timely interventions. Moreover, well-maintained equipment tends to have a longer lifespan, which ultimately results in cost savings over the long term.

Monitoring of machines is the one of the best way of avoiding the sudden brake down of the machines, It can be done by maintaining the daily checklist and checking the all the data and readings on regular basis, any changes is the data can help you to find the behavioural changes in the machine which we have to attend in PM Schedule.

It is utmost important to follow TPM and to have it effective, KPIs like MTTR and MTBF play a pivotal role. Shop floor team sensitization and bringing such culture into DNA are other key aspects for having maximum Availability Factor within OEE, which also has an integration effect over Performance Factor and consequently Quality Factor of resultant Product.

Some of the things that are of paramount importance and very critical when using high-speed, high production machines: - Preventive maintenance scheduling - Planned downtime - Inventory of critical long lead time spares - Proper training of operating and maintenance technicians. - And most important is regular clean-up of equipment

Understanding how a lubricant degrades is the first step to helping prevent a breakdown. Machinery lubricants are sacrificial in nature, hence they will break down from the moment they enter the machine as they have to perform their functions. However, some lubricants can degrade faster than others namely due to the environment in which they operate. If there is a high source of contamination, or the environmental conditions induce higher temperatures or pressures further causing a degradation mechanism to occur, then these can all lead to the lubricant degrading at a faster rate than it should. In these cases, a thorough RCA should be conducted to ensure that the correct lubricant is being used and the environment also supports its use.

Hi speed machines need to lubricate periodically.To deside a period of checking you have to monitor your machine for Tempreture,sound and vibration by this parameters log data you can deside the period of lubrication,replacement of bearings and ware out parts.

Hoje no mercado temos uma grande variedade de lubrificantes de alta performance por exemplo, ja temos boas tecnologias que podem proporcionar saltos importantes no desempenho dos equipamentos, principalmente os de alta velocidade.

Utilizing ultrasonic lubricators greatly reduces the chances of over or under lubricating. There are numerous out on the market and all are great for it.

Automatic lubrication systems would eliminate the need to halt machinery for manual lubrication. Lubricating while bearings are rotating improves the distribution of lubricant. Integrating monitoring devices into the lubrication system allows operators to leverage big data. By recording the entire lubrication process, early warnings of machine failures can be detected, enabling preventive action. Confirm that sensors are functioning correctly. A bypassed sensor could disrupt lubrication. Regularly check and refill oil and grease reservoirs according to the maintenance schedule. Open the area requiring lubrication to verify if the lubricant is reaching its intended goal. Damaged carrier pipes may not trigger a “no lubrication” alarm.

If you are a systematic organization it is very easy and less time consuming task Follow these basic steps. 1. Look and search basic JH ( JISHU HOZEN) chech sheet from last preventive maintenance . See for any abnormalities mentiond or missed points. 2. Check last done preventive maintenance look for any abnormalities mentioned or miss points 3 check with pm schedule. 4.Check past history kokatora sheet and process fmea for SOD or RPN for related machine If you have systems in place you can overcome before an hour.

A thorough TPM or OPC program leads to a more engaged operations work force which leads to better running equipment and less emergency maintenance

We can train operators but only allow them on basic knowledge. This will help technicians to be able to isolate further and deeper when performing troubleshooting.

Our foremost concern is always understanding why the machine is wearing out. Most often, the issue stems from improper operation. New technologies such as trochoidal milling can quickly lead to problems if applied incorrectly.Exactly here is where we need to focus, by providing targeted training to employees. Well-structured training programs, based on predefined plans, consistently reduce machine downtime and wear.

Preventing breakdowns in high-speed machinery through operator training is like teaching someone to drive safely to avoid car trouble. Operators need to know the machinery inside out, similar to understanding how to handle a car. Provide clear instructions, like a driving manual, on how to operate and care for the machinery. Teach them to notice any signs of trouble, just like a driver checks for strange sounds or dashboard warnings. Encourage a routine maintenance schedule, such as regular oil changes for a car. If something doesn't seem right, make sure operators know to report it immediately, preventing small issues from turning into big problems.

Normalmente las actualizaciones, no son lo mejor para la máquina, a veces en lo mecánico una actualización supone un lío impresionante de partes móviles que a la larga suponen más averías y más mantenimiento, en cuanto a software, la máquina tiene que estar diseñada para soportarlo, no quiero decir que no se pueda actualizar, sino que vaya mejor con lo que tenía antes.

A atualização tecnológica dos equipamentos é fundamental. Principalmente para continuidade da operação, mantendo a perfomance, custos competitivos e rentabilidade da negócio. Importante entender que o “momento atual” está sempre em transformação, seus concorrentes certamente estão se movimentando e evoluindo. Se você não se atualizar, com certeza estará em um patamar inferior a cada dia.

Antes de alguna actualización es necesario entender las necesidades del proceso operativo. Ya que una actualización de maquinaria si el proceso no es represantivo generaría un gasto innecesario,

Upgrading machines typically result in operation improvements, but not all upgrades are equal. Make sure the potential upgrade has been thought out and planned out for the machining processes and any potential process impacts are identified and evaluated. Some machines don't actually need upgrades and having enough spare parts on hand for the production life can be just as beneficial.

Treine seus Operadores- é um ótimo método de manter um bom funcionamento das máquinas e equipamentos pois o Operador é o primeiro mantenedor a iniciar uma manutenção, por ter mais conhecimento q o mantenedor em algumas ocasiões.

Preventive maintenance schedules can be established to regularly inspect identifying and addressing potential issues which can cause break down. Additionally, implementing real-time monitoring systems can help detect early signs of malfunction, allowing for timely intervention. Upgrading components or software to enhance durability and performance can also reduce the risk of breakdown.

If you understand your body and take good care of it, looking after the machine under your care becomes a cakewalk. When you truly understand your body and make a conscious effort to look after it, taking care of the machine that is your physical form becomes an effortless task.

Machine breakdown can be a major obstacle for virtually any organization. 1. Failure to follow the manufacturer’s instructions is one potential cause of machine breakdowns. 2. Maintenance team should be highly knowledgeable about machinery components, while the operators should have sound instruction on how to utilize the production machinery safely and successfully. 3. Catch early warning signals from machine using sensor, alarm. 4. Don’t overwork the equipment-Preventive maintenance (Time based) should be carried out to reduce unplanned machine downtime. It’s just like getting your car serviced at recommended intervals. 5. Condition based monitoring-CBM 6. Be Proactive, not reactive.

CLIT: The acronym described as (Cleaning, Lubrication, Inspection and Tightening) is a tried and tested tool for preventing high speed machinery breakdown. To follow this tool meticulously means that the Operators are working autonomously by Cleaning the lines at the beginning of each shift. They clean to inspect ( for any occurrence of abnormalities or defects) and this is followed by Lubrication to prevent wear and tear, friction, excess heat and other related issues. Lastly, tightening is done on the observed workloosed bolts and nuts. This will ensure consistency and continuous reliability of the high-speed lines.

With respect to high critical machines, we can 1. Continuously monitor the product and process parameters of the machine and watch out for any variation in trend of it. 2. Identify the critical and long lead spares of the machines in order to replace if it fails. 3. Always have a skilled person whenever the machine runs to attend the breakdown and release the machine for production. 4. Have the machine maker informed of the running condition of machine and set them ready for online and offline support whenever required. 5. Release the machine weekly once for an hour or two for special maintenance to focus on very specific points to maintain running condition 6. Keep 2/3 days stock for customer to protect them if breakdown occurs