In the world of machinery, downtime is the last thing you want as a plant operator. Maintenance is the oil in the gearbox that keeps your equipment running smoothly and prolongs its life. But what exactly does the term "maintenance" mean, and how does it differ from obvious terms such as service and inspection? Our feature article gives you an overview and important tips for optimising your machinery!
Content
Definition: maintenance measures
Advantages of maintenance measures
4 types of maintenance measures
Best practices for the effective implementation of maintenance measures
Obstacles, that make effective maintenance measures more difficult Planning maintenance measures with the aiomatic software
Definition: maintenance measures
Maintenance measures are all targeted activities that ensure that machines and systems function perfectly. They include regular maintenance, repairs and adjustments to avoid unexpected breakdowns and costly downtime. Targeted maintenance measures keep production machines efficient and reliable, which ultimately increases productivity and saves costs.
Advantages of maintenance measures
Effective maintenance offers numerous advantages:
Increased availability and productivity: Regular maintenance reduces unplanned downtime.
Cost control: Predictive measures reduce maintenance costs in the long term.
Improved safety: Continuous checks minimise safety risks.
Sustainability: A well-maintained machine has a longer service life and reduces the consumption of resources.
4 Types of maintenance measures
Inspection: Regular checks on the health of the machine, e.g. visual inspections and functional tests, in order to recognise wear or damage at an early stage. One example is checking production robots for mechanical wear and malfunctions.
Maintenance: Scheduled measures to maintain the state of health, such as cleaning, lubrication and replacement of wearing parts. One example is the regular replacement of hydraulic filters in production machines to maintain their efficiency.
Overhaul: Repairs to restore health / functionality after a defect. For example, the replacement of a defective gearbox in a production machine.
Improvement: Measures to increase efficiency or safety, such as retrofitting machines with modern sensors for better monitoring. For example, the installation of vibration sensors in order to become aware of bearing problems at an early stage.
Best practices for the effective implementation of maintenance measures
Strategic planning: A clear maintenance strategy is crucial in order to take the right measures at the right time. Be sure to consider the specific requirements of your machines and production processes.
Use of maintenance software: Tools such as aiomatic's AI-based software support data collection and analysis of sensor data as well as early detection of faults. Incidentally, our solution also offers a visual root cause analysis so that targeted maintenance work can be carried out.
Regular staff training: Training ensures that staff are familiar with the latest technologies and procedures, which increases the effectiveness of maintenance.
Use of predictive maintenance techniques: Predictive maintenance solutions use machine learning and data analysis to make predictions about potential failures, enabling proactive measures and maximising machine availability.
Documentation and logging: Careful documentation of all measures carried out is the key to success. It not only supports traceability, but also the optimisation of future maintenance strategies.
Obstacles that make effective maintenance measures more difficult
Poor data quality and availability: If data on the condition of machines and systems is inaccurate or incomplete, it is difficult to carry out necessary maintenance work in a timely and effective manner.
Lack of expertise: A lack of technical knowledge and experience can lead to maintenance measures not being carried out optimally, resulting in inefficient processes and higher failure rates.
Resistance to new technologies: There is often a reluctance to introduce new technologies that would be necessary for more effective maintenance. This resistance can be due to fear of change or a lack of confidence in new systems.
Technological complexity: The increasing complexity of modern machinery and equipment presents additional challenges as more specialised knowledge and technology is required to maintain and repair them.
In addition to these points, budget constraints can also play a role, as there are not always sufficient financial resources available for the implementation and realisation of necessary maintenance measures. A lack of planning and coordination within the company can also lead to inefficient maintenance processes.
Planning maintenance measures with the aiomatic software
The aiomatic software revolutionises the planning of maintenance measures! Artificial intelligence is used to precisely predict maintenance requirements and thus significantly increase efficiency. Instead of relying on rigid maintenance plans or reactive repairs, aiomatic enables data-driven, predictive maintenance that minimises unnecessary costs and wasted resources. See the benefits for yourself and book a free demo to find out how aiomatic can optimise your maintenance strategy.
FAQ
What is meant by maintenance?
Maintenance includes all measures to maintain and restore the functionality of machines and systems.
Why are regular maintenance measures important?
When should maintenance measures be carried out?