The maintenance of your production machinery is an essential aspect of any production site. However, maintenance costs can quickly add up and become a major financial burden for the company. Fortunately, there are several ways to reduce maintenance costs. This will not harm the quality and performance of the machines. In this article, we will explore some of the most effective strategies for reducing these expenses. Although necessary, let’s avoid waste as much as possible!
The method :
Set up a preventive maintenance programme
Regular preventive maintenance can help avoid costly breakdowns in your machinery. Potential problems need to be identified and repaired before they become more serious. By establishing a regular preventive maintenance programme for each machine, you can ensure that machines are regularly inspected and serviced. This will reduce your maintenance costs in the long term.
Use machine monitoring technologies
Machine monitoring technologies such as IoT sensors, diagnostic software and quality control systems can help detect machine performance issues before they develop into bigger problems. ProcessTrak, our dedicated process value monitoring tool, lends itself very well to this exercise. It is even more powerful when coupled with our Machine Learning. These IoTs can help predict potential breakdowns. This allows maintenance technicians to repair machines before they break down!
Train staff in basic maintenance
Training staff in basic maintenance can reduce maintenance costs by reducing the need to call in external service engineers for minor problems. By training your staff in basic maintenance, you can ensure that minor repairs are carried out quickly and efficiently, without having to spend money on sub-contractors.
Planning maintenance during shutdown periods
Scheduling maintenance during periods of downtime can reduce the cost of work by minimising the loss of production due to machine stoppages. By scheduling maintenance during holiday periods, you can minimise the impact of maintenance on overall production. This will reduce your costs associated with lost production.
Use quality spare parts
Using quality spare parts can reduce maintenance costs by reducing the frequency of repairs required. Quality parts are more durable and resist wear better than inferior parts. Although the purchase cost may be higher, this will enable you to produce for longer. That’s how you can reduce the impact of your maintenance expenditure.
Monitor machine performance
Monitoring machine performance can help to detect potential problems before they become actual problems. By monitoring machine performance, you can detect a number of things. Abnormal scrap generation, an increase in unplanned stoppages, or a slowdown in throughput. These clues can point to future problems.
To sum up
It is important to implement a preventive maintenance strategy to reduce maintenance costs. This strategy consists of regularly planning machine maintenance by carrying out regular inspections, replacing worn parts before they cause greater damage, and setting up a regular maintenance schedule to avoid unforeseen breakdowns.
Finally, employee training is also a key element in reducing maintenance costs for industrial machinery. Well-trained employees are able to detect problems earlier, carry out minor repairs and perform preventive maintenance. In addition, well-trained employees can reduce the risk of errors and costly damage caused by the misuse of machinery.
In conclusion
Reducing maintenance costs for industrial machinery is essential to maintaining machine quality and performance, while reducing operational costs. By implementing a preventive maintenance strategy, choosing the right spare parts, using the right consumables and properly training employees, companies can keep their equipment in perfect working order while minimising maintenance costs.
To keep up to date with all the latest TEEPTRAK news, visit LinkedIn or YouTube
You may also be interested in