Preventive maintenance

Preventive maintenance

The right tool and proper maintenance help.

„A forest worker painstakingly crushes a giant stack of wood and comes slowly and effortlessly forward. Walkers come by and watch the woodworker for a while, then ask him why he does not sharpen the saw first. The woodworker shakes his head and says: „They see my work. I have no time, I have to saw. „

A still stumbling-up existence continues the preventive maintenance in some production companies. Due to lack of specialist staff and budget reductions can only be reactively. Machine failures and disaster damage must always be repaired. Preventive maintenance with maintenance and inspections lacks time, staff and money. This is a fallacy, because the costs are even rising as a result of a lack of investment in the production machines, the company’s infrastructure and ultimately the maintenance. The utilization of production machines can be stabilized and increased through targeted and planned maintenance with maintenance / inspection intervals, through a consistent documentation of maintenance and the resulting weak point analysis and ultimately the removal of weaknesses.

Workflows can be standardized. Instructions and work instructions help the supervisor to implement them. By means of standardized work plans, production can be included in maintenance routines. Autonomous maintenance performs clearly defined tasks from the routine catalog and supports the operational maintenance. Thus, lubrication work or the reading of machine data and parameter comparison, filter control and changeover can be carried out. Investing in a preventive maintenance that can work well organized and structured is very well spent money.

An example – on the road as a service engineer mechanical engineering.

It is Thursday, only the use at the 2000to press. The oil circulation lubrication at a large eccentric press has failed a customer. The pump should have a defect and I go at 6.30 clock. In the traffic I need 55 min to be on site. The customer is considered to be a difficult business, as a managing director he carries out a punching shop which he managed from the garage business to the considerable medium-sized company. A performance that has my greatest respect and is no longer everyday in our time. Unfortunately, a patriarchy style is not appropriate for all areas.

On the ground, I look at the situation more closely and find a frightening situation in the foundation basement. The hydraulic unit is provided with an open cover. A leakage from an ailing 2-inch compressed air duct spills dust and dirt all the time. The whole dirt is landed in the aggregate, of course, and has probably caused the damage.

The mechanic comes around 8.00 clock and together we seal first the compressed air line. Then we look at the hydraulic unit and find dirt on the bottom of the tank. The oil seems more suitable for road construction, for lubricating the guides it is rather contraproductive. We build the pump and make sure that this is defective, through the dirt in the oil, the suction screen has been added so that the pump probably ran dry. A missing or bridged monitoring of the unit / filter has then led to the total failure. As the pump builds apart, our initial suspicion then confirms.
Typical case of lack of preventive maintenance.

The customer would like to quickly install a new pump and then continue to produce quickly. On my suggestion to clean the container, to flush the lines, to fill new oil and to integrate a suitable side stream filtration reacts almost already allergic. After a tough discussion, we agree on a compromise; Immediately clean the tank and rinse the system and fill with new oil, install the pump with filtration and monitor the pressure filter again with a pressure switch. We prepare the secondary stream filtration completely and close it at the next standstill of the plant. In the meantime, the oil is cleaned with a mobile filter unit until all the foreign substances are removed. In addition, we install a suction glass into the unpressurized return line, which allows maintenance to look more closely at the returning oil. At around 1.00 pm we are with the whole assembly, cleaning, oil change and connection of the monitoring through and the plant can produce again. The installation of the secondary flow filter system is largely prepared by us and must only be connected by the mechanic and electrician on site at the next standstill.