Maintenance does not always go according to plan. In the worst case, this can be very costly for companies, as machine breakdowns can cost large industrial companies up to $100,000 per hour. To prevent this from happening, here are the six most common maintenance mistakes and how to avoid them.
1. Too little, too late
The biggest mistake companies can make is to neglect maintenance in general. If machines are only maintained irregularly or inadequately, small problems can develop into major damage. These lead to costly machine downtime and equally expensive repairs. It is therefore highly recommended that equipment and machines be inspected regularly.
But even with routine maintenance, machines should be checked regularly to identify potential problems that may not be part of the usual maintenance plan. Ideally, you should carry out daily, weekly and monthly inspections. For example, the operator might do a quick check at the start of each shift, and maintenance staff might do a full inspection on Monday morning.
2. Lack of attention for the machine
Machines wear out faster when they are overstressed by high production rates or improper use. This also increases the risk of failure. Be sure to adhere to upper limits on production, processed material thickness or permissible weight.
In addition, even your machine needs some attention. The best way to show this is to give it a thorough cleaning on a regular basis. Dirt, dust and debris can affect machines and components. This leads to premature wear and tear and the machine loses performance.
3. Ignoring smart maintenance technology
Predictive maintenance is one of the most helpful technologies for identifying and fixing problems early before they lead to failure. In recent years, it has therefore become an integral part of maintenance in companies. The many success stories surrounding predictive maintenance show that the investment is worthwhile for companies of all sizes.
In addition, many modern machines already have sensors or warning systems to alert you to potential problems. It is particularly careless to ignore these warnings. This can lead to serious errors or failures. It is therefore important to take every warning signal seriously and quickly look for possible causes of the error message.
4. Lack of documentation:
Documentation is often one of the most annoying tasks in maintenance. But inadequate documentation can quickly lead to chaos, inefficient maintenance and errors. So in this case, the motto is: persevere and keep accurate documentation.
Checking, adjusting, replacing batteries or accumulators, fitting, resetting, lubricating, cleaning, preserving, adjusting system components, checking fill levels… All of these are typical recurring tasks and safety measures during maintenance. They must be recorded in a maintenance plan or documentation so that companies can easily keep track of the condition of the machines. They also help to track maintenance histories and optimize maintenance plans. Because if you know exactly what work was carried out during preventive and reactive maintenance, you can use this data to identify the causes of problems and adjust your maintenance program accordingly.
5. Missing or incorrect spare parts
Especially for components that wear out quickly, it is important to keep a sufficient supply of spare parts in stock. This means that old and broken parts can be replaced quickly without the machine being down for long periods. In recent years, this task has been particularly challenging due to supply chain bottlenecks. Many companies have therefore had to switch to parts from other manufacturers or use new sources for components.
Nevertheless, care must be taken to ensure that the components installed are suitable for the machine. Non-original or unsuitable spare parts can affect the performance of the entire machine and shorten the service life of the components or even the entire machine.
6. Inadequately trained maintenance personnel
The human factor should not be underestimated either. Inadequately trained staff may not recognise problems during maintenance or make incorrect diagnoses. This makes maintenance inefficient or, in the worst case, even leads to damage. Therefore, there should always be sufficient staff available for maintenance and they should be well trained.
Ideally, training should be considered, discussed and included in the project plan right from the start. Identify your most important operations and maintenance staff from all shifts and ensure that they are involved early on. It is particularly helpful if they are already there during installation and commissioning. This way they are very familiar with the machine and can also train the rest of their team.
A visit from a field service technician can also be a good opportunity to request further training, ask questions or refresh what you have learned.
Maintenance final tip
Maintenance is a central part of working with machines. That is why it should be taken into account when purchasing the system. Think about how large your maintenance and support team needs to be. Ask your best mechanics to draw up detailed inspection and maintenance plans and insist on their careful implementation. Always seek support, for example from the machine manufacturer’s technical support. Perhaps there are still unused training opportunities here? And in the event of an emergency, find out whether a technician can be quickly available to carry out repairs in the event of a breakdown. This way, hopefully nothing will go wrong during maintenance!
Images: Adobe Stock
