How Scheduled Maintenance Can Extend Machine Life

Why to Run to Failure is Costing You  

‘Reactive’ or ‘run to failure’ maintenance addresses problems after they occur. Operators will deliberately leave equipment running without maintenance until it breaks down. This can cause expensive downtime, lower productivity and often higher repair or replacement costs.

Run to failure is still used by 52% of manufacturers, but it is being quickly replaced by predictive and preventive maintenance.²
 

What is Planned Preventive Maintenance?  

Planned Preventive maintenance (PPM) is a proactive approach to equipment care. It involves routine inspections, cleaning, parts replacement, and performance monitoring. This prevents unexpected machine breakdowns and extends their lifespan. 

Preventive maintenance (also referred to as preventative maintenance) are terms for the same thing, and both are commonly used. An alternative term is ‘scheduled maintenance’.

Benefits of Scheduled Maintenance  

A well-implemented PPM schedule offers several significant advantages:  

• Extended Equipment Lifespan: Routine maintenance reduces wear and tear on machinery, extends equipment life and maximises return on investment.  
• Reduced Downtime and Production Loss: PPM maintenance minimises unexpected equipment failures, ensuring more consistent production schedules and reducing costly downtime.  
• Improved Efficiency and Safety: Well-maintained machines perform more efficiently, reduce energy consumption and improve worker safety.  
• Cost Savings: Requires investment but lowers costs over time by reducing repair and extending machine life.  
• Enhanced Product Quality: Properly functioning equipment helps maintain consistent product quality, which leads to greater customer satisfaction and reduces returns or rework.  

Key Components of Preventive Maintenance 

Preventive maintenance involves several core elements that together create a comprehensive maintenance strategy. Here’s a breakdown of essential activities. 

• Scheduled Inspections
  Scheduled inspections are crucial as they allow technicians to spot worn-out parts or leaks before they result in machine breakdowns. According to research, the average facility spends 33 hours each week on scheduled maintenance, up from 20 hours over 2020 data.³ 
• Routine Cleaning
  Over time, dust, debris, and oil build-up can affect performance, reduce efficiency, and lead to overheating. Regular cleaning not only extends equipment lifespan but also contributes to a safer work environment. Parts cleaning is a critical step in removing harmful contaminants from components. It reduces friction and wear, helping maintain peak operational efficiency. 
• Parts Replacement
  During inspections, technicians may identify parts that are worn and nearing the end of their useful life. Proactively replacing these parts can prevent a minor issue from escalating into a major repair.  
• Performance Monitoring
  Monitoring key performance indicators (KPIs) for each machine is essential for a well-functioning PPM. By tracking metrics like operating speed, vibration levels, and temperature, technicians can identify early signs of potential issues. 

Building a Preventive Maintenance Schedule  

A preventive maintenance schedule must be tailored to your plant’s unique equipment and operating conditions, but it should always include the following steps:   

• Audit Your Equipment: Begin by listing all machinery, identifying each machine’s critical components and ideal maintenance intervals.  
• Assign Frequency of Tasks: Differentiate between daily, weekly, monthly, and yearly tasks. Assign tasks based on each machine’s maintenance needs.  
• Plan for Downtime: Schedule maintenance during planned downtime periods or low-production hours to minimise disruptions.  
• Review and Update: Adjust plans to reflect changes in production levels, equipment age, or new technologies.  

The Role of Safetykleen in Preventive Maintenance  

Safetykleen offers a full-service parts cleaning solution, including machine rental, chemistries, waste removal, servicing and support. As a trusted partner, Safetykleen understands the value of extending the lifespan of your manufacturing machinery through regular scheduled cleaning. 

Contact us if you’d like support in optimising your parts cleaning. Our team are available for a free site survey and tailored advice.  

SOURCES

1. The True Cost of Downtime (Siemens)
2. The Maintenance Function, Like Manufacturing Itself, is a Rapidly Changing Environment (Plant Engineering)
3. 2021 PE Maintenance Report (Plant Engineering)