Most industrial machinery used today can be effectively referred to as “legacy” hardware and is older than at least 10 years. There are several reasons for this, the most obvious being that if it works, why replace it? Another reason is that newer technologies, while vastly improved, require a scale of investment that companies cannot justify.
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It's challenging to keep ageing equipment running in tip-top shape. Routine maintenance and servicing can ensure the necessary components remain in relatively good condition. But when it comes to dealing with problems, most maintenance plans are reactive and only require action after something has gone wrong.
A more proactive approach, using preventative maintenance, is the better route. Not only does it keep the hardware healthy and performing at top levels, but it also significantly reduces downtime, if not altogether eliminating the kind of equipment failures that result in a temporary plant shutdown.
Preventative maintenance is ideal for equipment of all types, of course, but for ageing hardware, it is known to prolong its lifecycle. After implementing a computerised maintenance management software tool (CMMS), the reliability of equipment can improve by as much as 35 to 50%. A CMMS tool helps automate the maintenance process, allowing for a preventative system instead of a reactive one.
So what are some tips for adopting a preventative maintenance plan? What can maintenance crews do to get a lot more out of ageing industrial equipment?
Stay on Top of Lubricants
Lubricants help reduce friction and tension for moving parts within a machine. Despite being an integral part of machine operation, many teams either forget to replace lubricants or neglect them entirely. When something goes wrong, however, oils are often the first part of a maintenance check.
Furthermore, when a large machine experiences severe issues, lubricants can often be analysed by experts to discern what’s wrong. Experts will look at particles in the used oil, which helps determine contaminants that indicate normal wear or more serious breakdowns.
Instead of waiting for a malfunction, engineers and equipment crews should ensure lubricants stay replenished. More importantly, they should always use the right type of lubricant, whether it’s oil- or grease-based. Hardware manufacturers often state what kind of lubricant is necessary for their machinery, so be sure to check the equipment manuals.
Keep Machinery as Clean as Possible
Depending on the work, your equipment could get lightly dirty or even filthy, especially if there are splashing materials or debris. Even if the working conditions are not especially messy, hardware will naturally soil over time from dust, dirt and other particles.
It is vital to regularly clean machinery, especially large equipment. It doesn’t matter if the hardware is brand-new or rebuilt and repurposed — it's possible to apply cleaning and finishing techniques with precision in the micron range.
The many moving parts and components inside are more likely to experience failures under sullied conditions. All seals and filters should be inspected for cleanliness and replaced when necessary. Breathers should be scrubbed and rinsed to avoid catching contaminants. Electronics and other elements should be wiped down to reduce moisture and waste. Whenever possible, the exterior casing of a machine should also be wiped down and kept clean.
For outdoor equipment, be sure to clean it before storage and keep it somewhere that’s sheltered from the elements. Even all-weather gear will break down and experience rust after exposure to wind, rain and other elements for an extended period.
As an added tip, any equipment or hardware left sitting unused for long periods should be routinely started and allowed to run for a short while. Fluids such as gas, oil and lubricants should be replenished to help flush out the old supply.
Document Everything, Train Everyone
Documentation exists to inform team members, old and new, how to administer the necessary preventative checkups. Reports should be filed to record service schedules. This will help ensure equipment is regularly maintained and allows teams to pinpoint a problem's source much faster during a malfunction.
Furthermore, everyone that comes into contact with a piece of equipment must be adequately trained no matter how much time they spend with the hardware. Cleaning machinery after use, for example, is everyone's responsibility. That also includes replenishing fluids and lubricants and ensuring the equipment is stored correctly and protected after use.
Implement the Right Technology
Newer equipment generally comes with information systems that help operators keep the hardware in shape. One piece of machinery might indicate when its running low on fuel and other fluids, for instance. But with legacy equipment, this isn’t always available. In that case, it’s crucial to incorporate the right technologies to assist preventative maintenance procedures, such as CMMS solutions.
The right technology will help companies stay accountable for routine maintenance, eliminating costly errors. CMMS tools are a suitable choice because they also provide key performance metrics about on-site equipment to keep everyone, especially decision-makers, informed.
Embrace the Cultural Shift
For most teams, the reactionary nature of everyday maintenance routines is challenging to leave behind. Operators are most often watching for possible malfunction signs such as shuddering, loud noises or unorthodox movements. All of the warnings go away with the right preventative maintenance plan, however.
It’s something that no one realises or quite understands until after the fact. Ultimately, the goal is to get ahead of those problems. If the symptoms do appear, it means the new maintenance routine is ineffective.
Therefore, a preventative plan essentially requires a cultural change across the entire organisation, imbuing new mindsets and procedures for dealing with equipment. It’s up to management and supervisors to embrace the cultural shift and encourage it amongst the ranks.
Preventative Is the Only Way
Preventative maintenance can be challenging to incorporate, especially for teams used to a more reactive process. But it is well worth the investment. And once everything is in place, most will realise it is the only and best way to handle servicing industrial equipment. Newer technologies can help alleviate some of the added requirements of a preventative plan if your budget supports it. In any event, the tips discussed here will help improve any maintenance routine you undertake.
Megan R. Nichols is a technical writer and blogger who covers manufacturing and industrial automation topics. She regularly contributes to sites like IndustryWeek, MHL Network, and ReadWrite. Megan also publishes easy to understand manufacturing articles on her blog, Schooled By Science, to encourage others to learn about these industries. Keep up with Megan by following her on Twitter.
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