Servicing production lines - how to ensure uninterrupted production and maximum efficiency

Estimated reading time: approx. 10 minutes

TL;DR:

• Systematic maintenance production lines prevents costly breakdowns
• Regular maintenance ensure the safety of workers and the high quality of products
• Service outsourcing reduces costs and speeds up the response to faults
• Cyclicality of maintenance work helps to plan production and avoid downtime
• Modernisation machines and the addition of robotic solutions increases productivity

Table of contents

• Importance of line maintenance
• Key elements to be serviced
• How often to schedule a service?
• Steps in the process of servicing production lines
• Benefits of outsourcing production line maintenance
• How do you measure the return on your service investment?
• Michale Automation - Your solution for line service
• Line servicing versus upgrading - when is it worth considering an extension?
• Example failure scenarios and how to resolve them
• Practical tips - how to stay in shape
• How do you start working with our company?
• Internal linking - information on other services
• Summary - key findings
• Incentive to act

Introduction

Servicing production lines is one of the key elements in maintaining a stable and efficient manufacturing process. Without proper maintenance and ensuring that machines are up and running, even the best production line can fail, causing costly downtime. In this article, you will learn why servicing production lines is so important, what activities are included in maintenance and how our company, Michale Automation, can help keep your production running. Read to the end for practical tips and the benefits of investing in professional maintenance services.

IMPORTANCE OF LINE MAINTENANCE

Regular maintenance

Servicing production lines is not just about responding to breakdowns. It is primarily constant inspection, preventive maintenance and servicing that prevents potential faults. According to industry estimates, scheduled maintenance work can reduce the risk of failure by up to 70%. In practice, this means not only less unexpected downtime, but also greater employee safety and higher product quality.

Impact on efficiency and costs

Fault-free line operation translates directly into the company's financial performance. Any unscheduled interruption in production can generate losses resulting from:

• Failure to meet delivery deadlines,
• The need to recruit a 'spot' service at a higher rate,
• Purchase of expensive spare parts on an express basis,
• Paying contractual penalties for failure to deliver the product on time.

Systematic servicing of production lines is an investment that, in the long term, brings tangible savings and helps to ensure a smooth flow of materials in the plant.

KEY ELEMENTS TO BE SERVICED

Main machines and equipment

In every production line, there are machines that are key to the industry - these can be, for example, packaging robots, presses, ovens, assembly equipment or transport systems. These are the ones that most determine production efficiency. During maintenance inspections, attention is paid to, among other things:

• Mechanical condition - wear on bushings, bearings, guides, belts,
• Control software - updates and correct operation,
• Safety systems - security and sensors,
• Contamination levels inside the machines.

Automation and control systems

In modern production lines, processes are usually automated and extensive control systems integrate the operation of many machines. Service in this area is not only about inspecting the wiring or replacing damaged electronic components, but also verifying the correctness of control algorithms. Errors in PLCs or HMI systems can lead to unpredictable line behaviour and even downtime.

Conveyor systems and feeders

Conveyor belts, rollers, infeed lifts or product recognition vision systems all work together to move raw materials, semi-finished and finished products smoothly. Regular servicing keeps them in good working order and prevents dangerous events, such as a jammed conveyor or damage to a line component, which could block the entire production process.

Robots and robotic workstations

Although not every production line needs to include industrial robots, more and more companies in Poland are opting for robotisation to increase competitiveness and optimise production costs. As an official distributor of SIASUN robots, Michale Automatyka offers implementation and service of such equipment. The regular inspection of robots includes, among others:

• Axis calibration,
• Overview of engines and transmissions,
• Verification of software and system security,
• Sensor and control system tests.

HOW OFTEN TO SCHEDULE A SERVICE?

Review cyclicality

One of the key questions is: how often to service a production line to minimise the risk of downtime? The answer depends on the intensity of use, the type of production and the degree of automation. In most cases it is recommended:

• Carry out a preventive review on a quarterly or six-monthly basis (this applies to less critical elements),
• Full general inspection once a year,
• Additional ad hoc inspections after each modification of the line or after changes in the production profile.

Importance of documentation and schedules

Reliably maintained technical records play an important role in maintaining cyclicality. By recording the dates and extent of maintenance work carried out, the company gains the ability to accurately plan future maintenance. In this way, recurring faults can also be spotted in good time and action taken to eliminate them at source.

STEPS IN THE PROCESS OF SERVICING PRODUCTION LINES

Diagnosis and condition analysis

The first step is a technical inspection, during which a specialised team assesses the condition of individual machines, components and control systems. Preliminary tests, such as load tests, are also carried out at this stage.

Replacement of worn components

After diagnosis, service technicians replace parts that are no longer serviceable. These may include bearings, drive belts, seals, filters or other types of components. In mechanised machinery, the quality of the spare parts used is crucial, so it is worth using reliable suppliers.

Updating software and security checks

With automated production lines, it is necessary to update controllers and HMI systems to the latest versions to ensure smooth operation and eliminate safety gaps. In addition, tests are carried out on all sensors and safety mechanisms.

Final testing and certification

At the end of the service, the line is test-run under various loads to check the stability of the process. If everything works correctly and the quality and performance parameters are within the set standards, the line can be returned to full production operation.

BENEFITS OF OUTSOURCING PRODUCTION LINE MAINTENANCE

Having an in-house maintenance department can be expensive, especially for smaller and medium-sized manufacturing companies. The alternative is outsourcing, i.e. outsourcing maintenance work to a dedicated external company. This solution allows you to:

• Access to qualified specialists with extensive experience in maintaining different types of lines,
• Accelerated service response in the event of a fault thanks to SLAs (Service Level Agreements),
• Optimise costs related to staff recruitment and training,
• Focusing on key areas of the business, rather than being distracted by service activities.

HOW TO MEASURE THE RETURN ON INVESTMENT OF A SERVICE?

Indicative cost and savings

The costs associated with maintaining and servicing production lines can range from a few to several tens of thousands of zlotys per year, depending on the complexity of the installation. However, the expenses incurred must be compared with the potential losses the company would incur in the event of downtime. Sometimes, the cost of one day of downtime exceeds the expense of annual maintenance many times over.

Company growth versus production stability

The service effectively eliminates the risk of unplanned interruptions, which helps to avoid delivery delays and maintain reputation in the market. For many purchasing departments or production managers, predictability is the biggest challenge. Therefore, access to a fast and efficient service enables production to be planned more precisely.

In addition, maintaining the high quality of products - made possible by efficient machinery - has a positive impact on customer relations.

MICHale AUTOMATICS - YOUR SOLUTION FOR LINE SERVICE

Comprehensive technical support
Our company, Michale Automation, specialises in the design and construction of machines and robotic production lines. However, that is not all. We also offer professional services for servicing, overhauling and maintaining existing solutions. We are well aware that every hour of downtime generates costs, which is why our specialists place great emphasis on fast diagnosis and effective repair.

Industry experience and access to parts
We work with leading component suppliers, so we are able to provide the necessary spare parts at short notice. Furthermore, as an official distributor of SIASUN robots, we offer service and technical support for these devices. We also deal with:

• Automation of existing processes,
• Consultation on selecting the best solution for a specific application,
• Installation and implementation of robotic workstations,
• Ongoing warranty and post-warranty support.

As part of the service, we also offer reconditioning and maintenance of production stations. A detailed description of the services can be found in our offer of service and maintenance stands.

LINE MAINTENANCE VS. MODERNISATION - WHEN IS IT WORTH CONSIDERING AN EXTENSION?

Combining service with modernisation
Often, in the course of inspection and maintenance work, it turns out that a production line requires not only a temporary repair, but also an upgrade or expansion. If a company notices an increase in orders or the need to improve quality, it is worth considering an upgrade, for example by adding a robotic station.

Examples of modernisation solutions

• Addition of a packaging module (using pick-and-place robots),
• Integration of a welding or grinding station (if such processes are carried out in the company),
• Improving vision systems for product recognition and quality control,
• Implementing collaborative cobots.

If you are considering expanding your facility, also visit automation and robotisation services.

EXAMPLE FAILURE SCENARIOS AND HOW TO RESOLVE THEM

Unexpected stop of the transporter

Issue: No possibility of transporting the raw material further in the process.
Solution: Rapid diagnosis, checking of drive mechanisms, limit sensors and, if necessary, replacement of the defective motor or belt.

Failure of the packaging robot

Issue: Bulk packaging of products on the line does not work properly, shelf life is reduced and backlogged products cause delays.
Solution: Calling in a specialist to test the axles and motors, verify the controller, update the software and calibrate the safety sensors.

Errors in the PLC control system

Issue: Line stoppage or incorrect transfer of data between machines.
Solution: Checking the system logs, reprogramming or replacing the faulty controller, post-repair testing including various operating scenarios.

PRACTICAL TIPS - HOW TO KEEP FIT

1. Invest in staff training

The employees who operate the line on a daily basis have the greatest influence on its condition. Very often, minor irregularities in the use of equipment cause problems to accumulate. That is why regular training helps them to understand the operation of the machines and the procedures to follow in the event of irregularities or the occurrence of an alarm.

2. Monitor key indicators

It is worth keeping track of parameters such as productivity, cycle time, product quality or downtime. A drop in productivity or an increase in quality defects can be an early signal that it is time to overhaul or adjust machines.

3. Make use of planned downtime

If your company has planned production interruptions (e.g. holiday periods), this is when it makes sense to schedule a thorough inspection or major maintenance. Doing so will help you avoid downtime during peak demand for your products.

HOW TO START WORKING WITH US?

Needs analysis and preliminary audit

We start our collaboration by understanding your production needs and requirements. We also offer an audit of your existing infrastructure - so we can identify areas where servicing and upgrading will translate into the greatest improvements.

Drawing up a service plan

We then prepare a maintenance schedule, tailored to the production facility's time capabilities. In doing so, we determine which machines require priority repairs and which activities can be postponed.

Implementation and after-sales support

Once the plan is approved, we proceed to carry out the work. During servicing, we try to limit the impact on current production as much as possible. Once the activities are complete, we conduct tests and train the team to correctly operate the upgraded or repaired line.

INTERNAL LINKING - INFORMATION ON OTHER SERVICES

If you are interested in additional solutions related to production automation - including robotisation of welding, packaging or painting, among others - we encourage you to read about them on our website. The implementation of modern solutions often goes hand in hand with improved safety, increased productivity and reduced employee costs. You can find detailed information here: opportunities for robotisation of various processes.

It is also worth remembering that in addition to robotisation itself, we offer comprehensive maintenance and repair services to complement the service we describe in this article.

To streamline day-to-day operations and ensure exceptional process stability in your organisation, our extensive service and maintenance offerings for existing workstations can also be useful: service and maintenance of robotic workstations.

SUMMARY - KEY FINDINGS

1. regular maintenance of production lines is an investment in the stability and uninterrupted operation of the plant, ultimately avoiding losses due to breakdowns and unplanned downtime.
2. inspections and maintenance should cover key machinery as well as automation systems or conveyors. This is essential to maintain the highest product quality and employee safety.
3 The cyclical nature of the service depends on the type of activity and the load on the line, but in most cases maintenance is recommended at least once a year.
4 Outsourcing maintenance work to an experienced partner such as Michale Automatics allows companies to focus on developing their offering and optimising costs, rather than building an expensive in-house team.
5 This translates into higher productivity, better product quality and protection from the consequences of possible failures.

INCENTIVE TO ACT

Do you have questions about production line service, maintenance or robotic implementations in your facility? Contact us - we will be happy to help you select the right service actions and plan a full maintenance schedule tailored to your needs. We also encourage you to check out our other articles on our blog, where we share our knowledge and experience in industrial automation, robotics and mechanical engineering.

Thank you for your time and we look forward to working with you - together we will ensure the reliability of your production!

FAQ

How often do you carry out an inspection of production lines?
This depends on the level of load and the type of machinery. Most companies opt for preventive maintenance a minimum of once every quarter or six months and additional maintenance work once a year.

Can production line maintenance be carried out without stopping production?
In some cases, minor repairs can be carried out without completely stopping the line, but for more serious work, downtime is sometimes unavoidable to ensure safety and service accuracy.

Does upgrading a line always involve high costs?
Modernisation can be incremental and tailored to the company's budget. Sometimes even small improvements, such as adding sensors or replacing controllers, can significantly increase efficiency and reduce operating costs.

Can a robotic line be serviced in the same way as a traditional line?
Robotic lines require robotics and software expertise. For this reason, it makes sense to choose a service company with experience in maintaining robots and automated systems.