Machine maintenance - how to ensure reliability and safety in modern production

Estimated reading time: 7 minutes

TL;DR:

• Regular maintenance of machinery is key to maintaining production continuity and worker safety.
• The choice of the appropriate maintenance model (reactive, preventive, predictive) affects the scale of costs and the risk of failure.
• Carefully prepared maintenance schedules and documentation help to prevent unplanned downtime.
• Working with an external service provider, such as Michale Automatics, solves the problem of a lack of qualified staff.
• Maintenance is not an expense, but an investment in the long-term efficiency and competitiveness of the company.

Table of contents

- Introduction
- Why machine maintenance is critical to production
- Types of maintenance - overview of methods and good practices
- Elements of a review plan in a manufacturing company
- Step by step through the machine maintenance process
- The most common challenges and how to solve them
- Cooperation with an external service provider and benefits for the company
- Conclusions and recommendations

Introduction

Maintenance of machinery is one of the key elements in the proper functioning of any production facility. Without regular service and attention to maintenance, it is more difficult to maintain efficiency, productivity and operational safety. Unexpected breakdowns mean delays, additional costs and often dissatisfied customers. Seemingly minor problems - if neglected - can, in the long term, lead to a major breakdown and downtime of the entire production line.

In this article, we explain why machine maintenance is indispensable, what the main steps are, what to look for when planning maintenance activities and how to apply lessons from industry practice. You will also learn what you need to keep your machinery fleet efficient, safe and able to meet today's market demands. After reading, you will find it easier to plan your maintenance regime and make decisions about working with a professional service provider such as Michale Automatics.

Why machine maintenance is critical to production

Regular maintenance is not only about ensuring the predictability and continuity of your machinery, it is also an investment in the growth of your business. Below, we highlight the three main reasons why you should take care of cyclical maintenance.

Safety of workers and the production process
Machinery in a poor state of repair poses a risk to staff and the environment. Their incorrect operation can lead to accidents, with legal consequences and costly downtime. Regular maintenance ensures that safety standards are met and minimises the risk of incidents.

Effectiveness and efficiency
According to selected industry reports, up to 40% of unplanned downtime on the production line is due to a lack of systematic maintenance. In contrast, well-maintained machines allow for optimum operation and stability in product quality. Over time, this translates into customer satisfaction and increased capacity.

Cost savings over the long term
Maintenance of machinery is sometimes seen as another item on the list of expenses, but in reality it is a preventive measure. Repairs carried out on an ongoing basis are cheaper than those as a result of major breakdowns. In addition, efficient machines use less energy, and this reduces the overall cost of running a business.

Types of maintenance - overview of methods and good practices

There are several approaches to machine maintenance. Each has its advantages and disadvantages. Below are the most popular models for effectively looking after your machinery fleet.

Reactive maintenance (repair after failure)
This is the simplest and also the least favourable model. Companies only react when something breaks down and the machine stops working. Costs are often higher because the breakdown occurs when least expected and requires immediate downtime. The reactive model may only be acceptable for ancillary equipment or those of marginal importance.

Preventive maintenance (planned and cyclical)
It involves carrying out regularly scheduled maintenance and replacing or repairing wearing parts. This significantly reduces the risk of sudden breakdown. Preventive maintenance makes it possible to make sensible cost forecasts and schedule servicing at times that are least disruptive to production.

Predictive maintenance (real-time diagnostics)
This is the most advanced model, which uses sensors, remote monitoring systems and data analysis. These allow the condition of key components to be monitored in real time. If symptoms of wear or unwanted vibrations are detected, the system automatically informs the operator of the need for service. However, this solution requires the implementation of monitoring systems, which entails higher initial costs. In companies with large production volumes and a large number of machines, this can be most cost-effective.

Elements of a review plan in a manufacturing company

The smooth execution of machinery maintenance requires a good plan. It is best based on the following pillars:

• Identifying priorities: Not all machines have the same impact on production. Service the critical equipment for continuity first, then the auxiliary machines.
• Review schedule: Create a calendar with dates for periodic maintenance. Also include additional checks after heavy use (e.g. during peak season).
• Inspection sheets and repair history: Documenting all activities allows you to better assess which components are most vulnerable to wear and tear. Consider the life cycle of each piece of equipment and manufacturers' recommendations.
• Responsibility for maintenance: Identify who in the company is responsible for the various stages of maintenance. This could be the internal maintenance department or an external service company.
• Budget for spare parts and upgrades: New components and chemicals and tools used for maintenance should be included in the planned budget.

It is worth remembering that requirements change over time and machines undergo upgrades (e.g. the addition of vision systems or collaborative robots). In such a situation, the review plan should be adapted to the new production infrastructure.

Step by step through the machine maintenance process

Preparing for the review
The first step is to gather information on the history of the machine in question - when and what repairs were carried out, whether there is room for preventive action. If the machine has been in continuous operation for several months, it is worth additionally foreseeing the replacement of wear items (e.g. filters, drive belts).

Inspection and measurement activities
Maintenance typically involves checking the condition of key components, analysing lubricant and fluid levels, checking seals, bearings or V-belts. Increasingly, companies are also using vibration, temperature or oscillation sensors to determine whether a component needs replacing in the coming weeks.

Cleaning and lubrication
Depending on the industry, dirt, dust, shavings or swarf can settle on moving parts and machine bodies. Removal of these deposits and proper lubrication are one of the foundations for maintaining smooth operation. The correct cleaning and lubrication agents significantly extend the life of bearings or gears.

Replacement of parts and components
After diagnosing the abnormality, the mechanic or service engineer decides whether the component needs to be repaired, adjusted or completely replaced. Here it pays to bet on quality parts. A cheaper replacement may seem more advantageous on the surface, but it will shorten the service life and result in additional costs.

Testing and commissioning
The final stage is to verify the operation of the machine after the procedures have been carried out. In particular, the correctness of movement, the absence of unwanted noises, the operating temperature or the stability of the production parameters are checked. If everything is normal, the machine is returned to service.

The most common challenges and how to solve them

Lack of experienced staff in the maintenance department
In many companies, especially fast-growing ones, the service staff cannot keep up with the expansion of the machinery fleet. The solution may be to hire additional specialists or to partner with an external maintenance company. As part of its offering, Michale Automatics works with customers on machine maintenance, allowing them to relieve the burden on internal maintenance teams and gain expert support.

Insufficient budget for maintenance and repairs
Sometimes companies forgo reviews in the face of other, more urgent costs. However, such savings often lead to postponing the problem. It is good practice to create a separate pool of funds just for maintenance, so that key activities do not have to be abandoned in a crisis situation.

Difficulty in accessing spare parts
For less standard machines, long waiting times for components can be a problem. The best solution is to build up an in-house parts warehouse or establish a partnership with a distributor to ensure fast delivery when needed. If a company uses a lot of similar equipment, it is usually a good idea to have a certain stock of original or high quality replacement components.

No flexible schedule
Assuming rigid inspection deadlines is sometimes insufficient. After all, it is possible that you suddenly receive a large order and a machine shutdown causes a bottleneck. Modern companies are increasingly relying on predictive maintenance using a variety of sensors. This makes it possible to postpone maintenance when parameters are still within the norm.

Cooperation with an external service provider and benefits for the company

Not every manufacturing company has an extensive maintenance department, the right number of engineers or experienced mechanics. In such cases, the support of external services, including specialists from Michale Automatics, comes to the rescue. Below, we outline why so many entrepreneurs opt for this form of cooperation:

• Access to specialists in various fields: With more complex machines that require knowledge of industrial automation, robotics or hydraulics, it is difficult to expect a single employee to master everything. An external service offers extensive expertise and fast support.
• Reducing the costs of the in-house maintenance department: Ongoing collaboration makes it possible to spread expenditure over time and eliminate the need to maintain full-time specialists for narrow issues.
• Guarantee of timeliness: A professional service company with proven procedures and facilities provides predictable response times, which helps with production planning.
• Possibility of comprehensive service contracts: They give you the reassurance that machine maintenance will be carried out at set intervals, with an external support team responding in the event of a sudden breakdown.

At Michale Automatika, in addition to building machines and production lines or implementing robotisation, we also have a service for servicing and maintaining existing workstations. For many of our customers, this is a convenient solution, as they use one company for modernisation, implementations and ongoing maintenance of the machine park.

- Explore the full range of services provided by Michale Automation: → Services
- Check our proposal in the area of robotisationwhich will optimise production and reduce labour costs.
- If you are interested in comprehensive fleet protection and maintenance, find out more about our offer: → Service and maintenance stands
- Thinking about automating your packaging processes? Check out robotisation of packaging in practice.

Conclusions and recommendations

- Remember that machine maintenance is not an additional expense, but a key investment in stable and safe production.
- Create or update a maintenance schedule based on actual data, manufacturer recommendations and failure history.
- Consider implementing predictive monitoring, especially if your machines are running continuously. This will reduce unplanned downtime and optimise resource utilisation.
- If you do not have enough qualified specialists in your company structure, work with a company like Michale Automation. You will avoid costly breakdowns and gain the support of experts with experience in new technologies, industrial automation or robotics.

Summary
Machine maintenance is the cornerstone of modern production. Without proper procedures, it is difficult to ensure trouble-free, efficient and safe operation. By scheduling maintenance at regular intervals and supporting yourself with a specialised service, you maximise the potential of your plant. You also increase the comfort of your workforce and ultimately gain a competitive advantage, as your production becomes more predictable and efficient.

If you want to fine-tune your machine maintenance process or are planning to implement comprehensive solutions to improve production - from robotisation to maintenance - contact the experts at Michale Automation. As an official distributor of SIASUN robots and an experienced industrial technology integrator, we can comprehensively support you at every stage of your machinery development.

We also encourage you to leave a comment and share your experiences with machine maintenance. By sharing knowledge and opinions, we are creating a community that strives together to improve production processes. Share the article if you find it valuable - you will help other entrepreneurs to ensure the reliability of their machines and increase the efficiency of their business.

FAQ

How often should a manufacturing company's machinery be overhauled?
The frequency depends on the manufacturer's recommendations, the intensity of use and the operating conditions. For most equipment, maintenance every 6-12 months is sufficient, although more frequent inspection is advisable for machines operating 24/7.

Is it worth investing in predictive maintenance?
Yes, especially if you have a lot of machinery running continuously. Sensors and monitoring systems can detect wear and tear on components before failure occurs, which translates into lower costs and less downtime in the long run.

How much does a professional machine service cost?
Costs depend on the type of machinery, the amount and frequency of servicing and the range of spare parts required. It often proves more cost-effective to permanently outsource servicing to an external company than to maintain an extensive maintenance department on site.