Unexpected and unplanned downtime brings unexpected and unpleasant costs. The costs often comprise of productivity loss to additional costs of damaged parts that could have been avoided if proper preventative maintenance were performed. In some cases, additional costs may include missed deliveries and unhappy customers. Additionally, an un-maintained machine becomes a ticking time bomb that can cost hundreds of times more in repairs than it would, had the issues been recognized and remedied during a regular planned preventative maintenance.
A machine that is down when it should be running gets awfully expensive. Consider cost of the labor force that is now sitting around on the clock not able to perform their duties. Also take into consideration the small part that became worn that would have been caught during a planned Preventative Maintenance. That small part will often cause a larger repair bill, damaging other parts as it breaks.
Keeping up with regular maintenance on equipment can mitigate the risk of unplanned downtime and keep production schedule on target.
Once you begin a preventative maintenance program you can plan downtime around your production needs. Performing preventative maintenances should be built into production schedules so packaging lines does not go down when you need it most.
Scheduling regular preventative maintenance gives control of production and a major reduction in how much will be spent on maintenance and repairs in the long run.
It is unfortunate that breakdowns occur when you least expect. Scheduling regular preventative maintenances helps minimise unscheduled break downs. For increased efficiency, add to regular maintenance scheduled downtime when operators can regularly care for the equipment. Productive Systems can also assist in the development of daily check lists for the machine operators as they start and end their shifts. The checklist will include machinery wipe-downs and checks for proper machine operation before and after the shift. These checks will improve efficiency of your preventative maintenance and the smooth running of your entire packaging process.
Machine operators should be experts in the machinery that they work with. We provide training and hands-on work that assist in fully understanding the machinery operators use to package products. We also provide training documents that show the basic cleaning and visual checks to be perform with ideal images.
Regular operators should be able to troubleshoot the machines they work using visual and audible cues. They should also know how to remedy them if it is an easy fix or to ask for help before causing further damage if they notice something more complex.
Knowledge of the process and function of the machines allows for better planning of what parts will wear and the run time expected from the worn parts before they fail. This also allows the parts to be changed before they slow down production.
Well maintained machines are reliable and run-in top performance. It is crucial to use past experience or parts supplier and technical information to gain an understanding of which parts wear faster on your machine. Keep a list of spare parts at hand. Minimum overhead costs constitute to minimum impact of the production schedule. Properly maintained machinery builds customer confidence and will rely on you to meet their needs for product replenishment hence keeping your customer happy.
Safety first for both employees and customers. Keep machines from failing and causing a hazardous work environment.
Regular preventative maintenance allows technicians time to inspect electrical and safety features for proper operation and to do more in-depth digging to find potential hazards that the machinery could create. Operator routine checks and operation can be limited and can miss hidden issues that a technician cannot miss when performing an in-depth preventative maintenance. Preventive maintenance not only saves costs, but it improves your reliability as a business and provides a safer work environment for your employees. Reduction in the number of breakdowns and after-hours callouts also sees a reduction in fatigue, stress and pressure of late night callouts on the employees.