In an increasingly digital world, the ability to create and manufacture, to scale, products that your market needs is one of the best offline business ideas. However, it’s not just about selling those products, it’s about getting them made, as well.
Delays and shutdowns on your production line can affect your bottom line, too. As such, here, we’re going to look at how you can keep it running smoothly through a few key predictive maintenance principles.
Monitor Your Equipment Health
If you have key machines that are vital to the production process, then installing a few sensors can help you monitor key elements of their performance, such as temperature, vibration, pressure, and run-time.
You can use this data to discover conditions that lead to failures (if they’re not already made clear by the manufacturers) and set alert thresholds so that your team is notified when they’re reaching the danger zone.
Excessive vibration could, for instance, lead to components loosening or be a signal, or worn bearings. The data can eventually lead to better servicing schedules.
Know Your Most Commonly Needed Parts
One of the most frustrating causes of downtime is waiting for a simple part needed to keep your machine going. High-use, operation-critical parts should be kept on hand at all times.
Whether it’s a belt that’s prone to wear and tear or a PVC tube that sees high volume use, identify the items that are most frequently replaced and ensure they always have space in your inventory.
You don’t have to hoard every potential replacement part; just strategically stock those that have a higher rate of replacement and work with the supplier to restock them as soon as they’re used.
Make Your Team Your Eyes And Ears
The right sensors can catch a lot of potential problems, but human insight is still highly valuable when it comes to predictive maintenance.
Take the time to train your operators and maintenance staff to recognize early warning signs of failure, such as unusual noises, output inconsistencies, and to be mindful of any subtle mechanical changes.
As such, those on the floor might be able to spot issues even before sensors trigger the alarms. Encourage a culture of reporting small irregularities, and create systems to document and respond quickly.
Schedule Your Routine Maintenance Smarter
A lot of inexperienced production line managers make the mistake of putting their routine maintenance on a rigid calendar. However, it’s often not time that’s the critical factor, but actual usage.
Machines don’t wear evenly, as some might operate around the clock while others are much more intermittent. By basing maintenance on operating hours, cycle counts, or sensor feedback, you avoid both under-servicing and unnecessary downtime.
This can help you ensure that your time and resources are spent more efficiently, while reducing the risk of failure to meet the specific needs of each machine.
You can’t prevent and solve every little problem before it occurs, but you can catch a lot more of them with the right focus on predictive maintenance, as shown above.
