??? Maximizing Efficiency: The Key to Preventive Maintenance for Automated Machines ??

In the realm of automation, where every second counts, preventive maintenance stands as the cornerstone of seamless operations. Today, I'm shedding light on the daily and monthly procedures vital for the upkeep of fully automated machines, along with the art of crafting an effective maintenance checklist.

• What is preventive maintenance?

Preventive maintenance is the process of regularly inspecting, servicing, and repairing automated machines to prevent breakdowns, malfunctions, or failures. Preventive maintenance is essential for automated machines, as they are often used in high-volume, high-precision, and high-speed production environments. Preventive maintenance can help extend the life span of automated machines, reduce downtime and repair costs, enhance safety and reliability, and prevent waste and defects because any downtime or error can have significant impacts on quality, efficiency, safety, and profitability. According to a study by the International Society of Automation, preventive maintenance can reduce maintenance costs by 25%, reduce breakdowns by 75%, and increase machine availability by 35% [4]. The purpose of this article is to provide an overview of the daily and monthly procedures for preventive maintenance for automated machines and to offer some guidance on how to design a checklist for preventive maintenance that is suitable for each machine. Why do you need a checklist for preventive maintenance?

• A checklist is a useful tool for planning and performing preventive maintenance tasks. A checklist can help you:

1. Identify the appropriate preventive maintenance tasks for each automated machine, based on its design, function, and usage.
2. Schedule the preventive maintenance tasks at regular intervals, according to the manufacturer’s recommendations or your own experience.
3. Keep track of the preventive maintenance tasks that have been completed and those that are pending.
4. Document the results and findings of the preventive maintenance tasks, such as the condition of the machine, the parts that need to be replaced, and the issues that need to be resolved.
5. Communicate the preventive maintenance tasks and results to the relevant stakeholders, such as the machine operators, the maintenance technicians, and the managers.

• ?? Daily Procedures:

For daily preventive maintenance, you should check the following items on your automated machines:

i. Visual Inspection: A quick visual scan sets the tone for the day, catching any potential issues before they escalate.

ii. Power supply and wiring: Make sure there are no loose connections, frayed wires, or signs of overheating. Replace any damaged or faulty components as soon as possible.

iii. Fluid Levels Check: Ensure optimal levels of fluids like oil and coolant, preventing overheating and system failures.

iv. Cleanliness: Keep machines spotless to prevent debris from disrupting their intricate operations.

v. Functional Tests: Verify all components are in top-notch condition through functional tests, ensuring safety and efficiency.

vi. Lubrication and cooling: Check the oil and coolant levels and refill them if needed. Clean any dirt or debris from the lubrication and cooling systems. Apply grease or oil to the moving parts as recommended by the manufacturer. Proper lubrication keeps the cogs from turning smoothly, extending the lifespan of crucial components.

vii. Software and Hardware Health Check: For automated systems with software, keeping an eye on updates and error messages is essential for seamless operations. also Test the sensors and switches for accuracy and functionality. Clean them with a soft cloth or compressed air. Adjust or replace them if they are not working properly.

viii. Safety devices: Inspect the emergency stop buttons, guards, fences, and interlocks for any damage or wear. Test them for proper operation and response. Repair or replace them if they are not safe or reliable.

• ??? Monthly Procedures:

For monthly preventive maintenance, you should perform the following tasks on your automated machines:

i. Detailed Component Inspection: Dive deep into each component; clean and maintain the machine surface and parts. Remove any dust, rust, or corrosion from the metal parts. Apply a protective coating or paint to prevent further deterioration. Check and replace any worn or damaged parts, such as belts, bearings, gears, or seals. that will ensure wear and tear are nipped in the bud.

ii. Calibration and alignment: Precision is paramount in automation. Calibrate and align the machine components according to the manufacturer’s specifications. Use the appropriate tools and instruments to measure and adjust the parameters. Record the calibration and alignment data and compare them with the previous values. Regular calibration keeps sensors and controllers in check.

iii. Tightening and Adjustment: Bolts and connections may loosen over time; regular tightening maintains stability and safety.

iv. Filter Replacements: Clogged filters can be the bane of smooth operations; replace them promptly to avoid hiccups.

v. Inspection and testing: Inspect and test the machine's performance and quality. Run the machine at different speeds and loads, check electrical systems that require special attention; inspect wiring and connections diligently to prevent hazards. Check for any abnormal noises, vibrations, or errors. Use the machine’s self-diagnostic features or external devices to detect and troubleshoot any faults.

vi. Documentation: Every maintenance activity should be meticulously recorded for future reference, aiding in trend analysis and decision-making.

• How to design a checklist for preventive maintenance?To design a checklist for preventive maintenance of automated machines, you can follow these steps:

i. Identify the machine components and functions: List the main parts and functions of the machine that need preventive maintenance. Group them into categories such as function, location, or type like electrical, mechanical, hydraulic, pneumatic, etc.

ii. Determine the maintenance frequency and criteria: Decide how often and on what basis you will perform preventive maintenance on each machine component and function. You can use the manufacturer’s recommendations, machine usage, the environmental conditions, or the historical data as reference points to determine the preventive maintenance tasks that are required, and the frequency and duration of each task.

iii. Training and Feedback: Ensure your maintenance team is well-trained and provides avenues for feedback, fostering continuous improvement.

iv. Specify the maintenance actions and standards: Describe the specific actions and standards that you will use to perform preventive maintenance on each machine component and function. You can use checklists, diagrams, instructions, or procedures as formats. Include the tools, materials, and safety precautions that are required for each action and standard. The template should include the following information:?

iv.1. The name and ID of the automated machine

iv.2. The date and time of the preventive maintenance

iv.3. The name and signature of the person who performed the preventive maintenance.

iv.4. The status of each preventive maintenance task, such as completed, in progress, or pending.

iv.5. The results and findings of each preventive maintenance task, such as the measurements, the observations, and the recommendations

iv.6. The comments and feedback from the person who performed the preventive maintenance.???? ?

v. Review and update the checklist: Fill out, review, and update the checklist regularly to ensure that it is clear, comprehensive, and customized for each machine. You can use feedback, audits, or inspections to evaluate and improve the checklist. You can also use software or apps to create and manage the checklist digitally. If possible, attach photos, videos, or documents to support your findings.

vi. Submit and store the checklist, and make sure that it is accessible and secure. You can use a paper-based or a digital system, depending on your preference and resources. You can also use a cloud-based or a web-based platform, such as deforms [1], to create, manage, and share your checklists online.

vii. Analyze and improve the checklist and use the data and feedback from the checklist to evaluate the performance and condition of the automated machines and identify areas and opportunities for improvement. You can also use the checklist to compare and benchmark the automated machines, and to generate reports and insights.

• What are some examples of preventive maintenance tasks for automated machines?

The preventive maintenance tasks for automated machines may vary depending on the type, function, and usage of the machines. However, some general preventive maintenance tasks that are common for most automated machines are:

1. Checking all machine components and replacing parts as needed, checking machine alignment to ensure all stations are level, checking machine bolts, levers, hinges, etc. to ensure everything is tightened to the correct tolerances, cleaning vision systems and camera lenses’ to ensure they are free of debris, cleaning debris from the machine and surrounding area to ensure the machine can operate efficiently [2].
2. Backing up controller memory, inspecting brake operation, Inspecting teach pendant, checking overtravel limits, Monitoring robot in motion, inspecting robot, harness, and cables, checking robot repeatability, listening for excessive audible vibration and noise, and Tightening external bolts [3].

• Conclusion

In conclusion, Preventive maintenance is a vital practice for maintaining and improving the performance and quality of automated machines. PM isn't just about fixing what's broken. However, it's about preventing breakdowns altogether. By designing a meticulous checklist for preventive maintenance with a robust daily and monthly maintenance regimen. you can plan and perform preventive maintenance tasks more effectively and efficiently and avoid the risks and costs of machine failure, propelling your operations toward unparalleled efficiency and success??. I hope this article has given you some useful tips and examples on how to design a checklist for preventive maintenance of automated machines. If you have any questions or comments, please feel free to contact me. Thank you for reading.

#PreventiveMaintenance #Automation #Efficiency #MaintenanceChecklist

• Reference

[1] Kevin Starr, “Preventive Maintenance for Automation,” ABB Ltd. 579 Executive Campus Drive Westerville, OH 43082. [Online].

[2] Rockwell Automation, “Preventive maintenance, A blueprint for building and perfecting a preventive maintenance program at your organization,” Fiix by Rockwell Automation Inc. All rights reserved. [Online].

[3] doForms, “Preventive Maintenance Checklist: Reduce Downtime With eForms,” Copyright 2024 doForms, inc. All Rights Reserved. [Online].

[4] Roselin Manawis, “Most Common Preventive Maintenance Examples,” SafetyCulture 2024, Dec. 13, 2023. [Online].

[5] SDC Technology, “Preventative Maintenance for Automated Machines,” ? 2024 Steven Douglas Corp. All rights reserved | Privacy. [Online].

[6] IBM Maximo, “What is preventive maintenance?” [Online].

[7] SDC Technology, “Preventative Maintenance for Industrial Robots,” ? 2024 Steven Douglas Corp. All rights reserved | Privacy. [Online].