Maintenance of production machinery - how to avoid downtime and optimise costs?

Estimated reading time: approx. 7 minutes

TL;DR

• Regular inspection and maintenance reduce the risk of failure and costly downtime.
• Unexpected failures generate multidimensional losses, including penalty interest and late deliveries.
• Original spare parts and specialised diagnostics guarantee long-lasting repair results.
• Staff modernisation and training is the key to extending the life of machines and reducing operating costs.
• Automation and robotisation require professional service support.
• Working with an experienced partnersuch as Michale Automation, ensures higher production efficiency and safety.

Table of contents

• Introduction
• The importance of efficient servicing of production machinery in the manufacturing industry
• The most common challenges and causes of shop floor failures
• Fundamentals of professional service
• Good practices that reduce the risk of machine breakdowns: examples and recommendations
• Service of production machinery at Michale Automation
• How to reduce the total cost of fleet operations?
• Summary of conclusions and implementation recommendations
• FAQ

Introduction

Servicing production machinery is one of the key elements in ensuring production continuity and efficiency. Any unplanned breakdown can mean significant financial losses, order disruptions and a reduction in plant competitiveness. Today, as companies struggle with rising costs and staffing difficulties, properly planned machinery maintenance is more important than ever. In this article, we explain what professional servicing looks like, what to look for when planning maintenance work and how Michale Automation can help.

If you are looking for tried-and-tested tips to help your company reduce unforeseen downtime and minimise costs, you will find out here what to look out for. We take this opportunity to tell you why properly planned maintenance of production machinery translates directly into longer equipment life cycles and increased efficiency throughout the manufacturing process.

The importance of efficient servicing of production machinery in the manufacturing industry

Whether a production facility has only a few pieces of equipment or operates extensive lines producing hundreds of thousands of units per day, the basis for efficient production is reliability. Every stoppage in the operation of machinery and equipment gives rise to a host of costs - from additional repair expenses, to penalty interest for missing deadlines, to increased expenditure on spare parts or forced stoppages of other production lines.

Against the backdrop of constant pressure to reduce costs and staff shortages, the role of an efficient service is growing. Properly planned technical inspections, maintenance and upgrades not only ensure the safety of employees and quality parameters, but above all guarantee the continuity of business operations.

What's more, the market is constantly changing and new technologies are introducing the possibility of extending the machine park with robotic workstations. W Automation MichaleAs an official distributor of SIASUN robots, we understand that more and more companies are betting on automation and robotisation. Therefore, the issue of professional servicing of production machines - both traditional and state-of-the-art - is fundamental to maintaining high productivity at competitive costs.

The most common challenges and causes of shop floor failures

Even the best-designed systems can fail if proper maintenance is not taken care of. The causes vary, although many can be eliminated by adhering to planned maintenance activities.

Unexpected mechanical failures and downtime costs

Among the common causes of machine breakdowns on production floors, mechanical problems related to overloading or insufficient maintenance of key components are most frequently cited. Delaying periodic replacement of bearings, seals or hydraulic components often leads to the so-called domino effect - damage to one seemingly minor component sometimes disables the entire line.

It is worth remembering that unexpected downtime does not only mean direct repair costs, but also losses due to delayed deliveries of products to the customer. As a consequence, the company may have problems in its relationships with contractors.

Errors in the maintenance of machinery during the daily operating cycle

Prolonged operation of machinery without strict adherence to maintenance instructions increases the risk of malfunctions. Many malfunctions are due to failure to follow procedures such as changing filters, lubricating components or calibrating sensors and drives.

When responsibility for regular maintenance is not clearly defined (e.g. split between different departments), it is easy for omissions and shortcomings to occur. It is also sometimes the case that employees with insufficient experience want to solve a problem instantly, using ad hoc temporary repair methods. This, in turn, can cause more serious complications in the future.

Fundamentals of professional service

The servicing of production machinery includes a range of activities aimed at reducing the risk of downtime and extending the period of trouble-free operation. Key areas include:

Machine diagnostics and repairs

Professional service begins with fast and precise diagnosis. State-of-the-art measuring equipment and the experience of the service technicians enable the source of failure to be identified in a short time.
- Repairs include mechanical, hydraulic, pneumatic, electrical and electronic systems.
- It is crucial to work with proven or original spare parts, which increases the longevity of repaired components.
- If necessary, replacements are used in quality certified by the industry.

Scheduled maintenance of equipment

Systematic maintenance is the foundation of infrequent and less disruptive breakdowns. Regular periodic maintenance and replacement of consumables reduce the risk of failures by up to several times.
- These include checking and adjusting machine operating parameters, servicing filters, bearings, V-belts, etc.
- Meticulous protocols and documentation give a clear picture of the history of the equipment being serviced, making it easier to plan future maintenance and investment.

Modernisations and optimisations

To remain competitive, it is not enough just to repair and maintain machines. It is also important to increase their productivity, ergonomics and operational safety.
- Upgrades can include replacing drives with more energy-efficient ones, installing modern control systems or improvements that increase operating precision.
- For older machines, the service can assess the scope for a major overhaul that will extend the life of the equipment by another decade.

Good practices that reduce the risk of machine breakdowns: examples and recommendations

Here are some practical approaches that go a long way to helping companies reduce the risk of faults and downtime:

• Set a clear schedule for reviews: It is best to determine at the implementation stage of a new machine exactly how many operating hours a basic and extended inspection should be carried out every.
• Implement a performance monitoring system: Bearing temperatures, vibrations or pressures in hydraulic systems can be measured automatically so that maintenance services receive an alert in the event of irregularities.
• Use proven components: Cheap replacements usually mean higher failure rates and shorter component life.
• Staff training: Skilled operators are able to respond to the symptoms of faults before they become a major problem.
• Document all service activities: Record every breakdown report and part replacement to spot recurring patterns and prevent them in the future.

Service of production machinery at Michale Automation

As a company specialising in the construction of machines and production lines, industrial automation and the implementation of robotic workstations, we know that even the most advanced technology requires proper maintenance. At Michale Automation, we offer comprehensive solutions for machine maintenance and service:

A comprehensive approach to maintenance

We do not limit ourselves to just repairing equipment and replacing parts. We analyse the entire process to identify sources of potential failure. As a result, we are able not only to restore the efficiency of machines, but also to recommend upgrades that maximise their potential.

Individual service plans

Together with the customer, we develop a detailed equipment maintenance schedule tailored to the specifics of the production line. This enables process downtime to be planned so that it has the least possible impact on production continuity. Find out more about the services provided by Automation Michale w
service division.

Rapid response and specialist support

We understand that time is of the essence, especially when on-time delivery is at stake. That's why we provide remote technical support and fast on-site interventions if the situation demands it. We have an experienced team of service technicians who are knowledgeable in both traditional industrial automation and the latest robots (including the SIASUN brand). As part of our offering, we also offer
servicing and maintenance of stations automated.

How to reduce the total cost of fleet operations?

One of the most common questions asked by managers and business owners is: "Does intensive maintenance simply not generate additional costs?". Practice shows that, on the contrary, systematic maintenance reduces failure rates and thus prevents greater expenses associated with major repairs or the replacement of entire components.

Data collected by independent research firms (and extensive industry experience) shows that investing in a planned maintenance model avoids most unplanned downtime related to faults. The cost of one major outage often exceeds the sum of minor maintenance activities spread over several months.

If a company is operating highly sophisticated machinery - such as industrial robots, automated assembly stations or systems equipped with vision sensors - proper maintenance becomes all the more important. Breakdowns of such equipment can have disastrous consequences for the entire production process, including the need to hire external specialists and waiting for hard-to-find spare parts.

It is also worth noting that improvements in efficiency can be achieved through upgrades - for example, replacing old control systems with more modern ones, which can often reduce energy costs or improve production management without replacing the entire machine.

Summary of conclusions and implementation recommendations

Regular servicing of production machinery is an invaluable aid to maintaining stable production levels, reducing breakdowns and cutting costs. Properly scheduled maintenance and repairs can save a company many unpleasant surprises in the form of costly downtime and dissatisfied customers. We have compiled the most important information and recommendations below:

• Plan service and maintenance in advance: Determine a detailed maintenance schedule and stick to it.
• Document every repair and replacement of a component: Fault history analysis enables the reduction of repetitive problems.
• Consider upgrades: Rather than investing in brand new machinery, it is often more cost-effective to upgrade key components.
• Take care of staff training: Staff should be able to quickly recognise the signs of a potential failure.
• Depend on fast service and proven partners: This minimises the risk of long-term downtime.

Finally, it is worth encouraging you to check out the full range of services related to the automation, modernisation and robotisation of industrial processes. An integrated cooperation model, in which one company is responsible for the implementation, servicing and possible subsequent expansion of production lines, provides a sense of security and prevents a return to square one.

If you would like to learn more about the possibilities of combining advanced solutions with SIASUN robots or if you are planning a complete or partial robotisation implementation, please feel free to contact our team. You will also find industrial automation and system integration solutions to effectively improve your production line.

Thank you for reading the article on servicing production machinery. We hope that with the above tips, your company will gain the tools to avoid costly downtime and your machinery fleet will serve even longer and more efficiently. If you have any questions, please feel free to send us a message, schedule a consultation or comment on our article. Also, share it with people who could benefit from the advice contained here, and follow our blog to keep up to date with the latest news in the world of industrial automation!

We encourage you to continue reading and collaborating:

• Explore our range of services in the area of robotics and automation:
  Robotics - services Automation Michale
• Find out how servicing and maintenance of robotic workstations works in practice:
  Service and maintenance stands

FAQ

How often should machinery be serviced?
The frequency depends on the intensity of use and the specifics of the equipment. On average, ranges of a few weeks to a few months are used for basic maintenance, and once a year or every two years for extended maintenance.

Is it cost-effective to service production machinery?
Yes. Systematic maintenance avoids major breakdowns and downtime, which generate many times higher repair costs and losses in terms of delays and contractual penalties.

Can you carry out repairs yourself?
Some minor repairs can be carried out by trained staff themselves, but for more serious faults or machinery of more complex design it is always worth using a professional service that has the necessary technical facilities and experience.