When you own a manufacturing plant, there are a lot of uncertainties you have to deal with. While fluctuations in production orders are one concern, machinery breakdowns and injuries from poor maintenance must not be overlooked. To avoid such scenarios, it is important to have a preventive maintenance routine and invest in an insurance policy, such as a workmen's compensation policy. Let's discuss both.
What is preventive maintenance in manufacturing?
Preventive maintenance in manufacturing is the practice of servicing machines and equipment at planned intervals to avoid sudden breakdowns. It includes inspections, cleaning, lubrication, calibration, and replacement of parts. With preventive maintenance, you can reduce downtime, extend equipment life, and boost production levels and quality.
Key differences in manufacturing preventive maintenance
Preventive maintenance in manufacturing focuses on scheduled inspections and servicing to avoid unexpected equipment breakdowns. Unlike reactive maintenance, which only occurs after a machine fails, preventive maintenance is proactive.
For example, in a bottling plant, conveyor belts are lubricated every month and sensors are tested quarterly. This proactive approach prevents sudden stoppages during production, which could otherwise halt the entire line and cause financial losses.
The key differences lie in timing and approach: preventive maintenance is scheduled, systematic, and reduces risk, while reactive maintenance is unplanned, costly, and can compromise safety.
Types of manufacturing preventive maintenance
Preventive maintenance can be classified into the following four types:
Time-based
In this, you pre-decide the maintenance schedule regardless of whether there is any fault in the machinery or not. One of the best examples of this is replacing lubricant oil every 2–3 months to prevent possible breakdown.
Usage-based
In this, maintenance depends on the operating hours or production cycles. For example, suppose you decide to overhaul the cloth stitching machine once it completes 500 hours or produces 10,000 units. Whether either of these is completed in a month or six months, preventive maintenance will be done only after that.
Challenges in preventive maintenance in manufacturing
Conducting preventive maintenance presents the following challenges.
Machine diversity
If you have installed machinery from different vendors, managing them not only increases the workload but also the risk of error. Given the diversity, each unit requires unique procedures, spare parts, and expertise. While one machine may need a lubrication schedule, another may demand sensor calibration.
Data reliability
Preventive maintenance depends heavily on accurate data from sensors, logs, and inspections. If a sensor malfunctions, readings get corrupted, or logs are poorly recorded, the entire maintenance process suffers.
Spare availability
If your setup has decade-old machinery or you have imported a few, then in the event of a breakdown, getting their spare parts can be challenging. This can lead to long lead times, putting your entire operation at a halt.
Scheduling conflicts
In a busy setup where orders are continuous, scheduling downtime for routine checks becomes difficult. If you postpone too often, the machines operate under strain. If you halt production too frequently, you lose output.
Condition variability
In a manufacturing plant, machines operate under different loads, temperatures, or environmental conditions. For example, a conveyor belt in a humid section of the plant may degrade faster than one in a controlled area. If you have a fixed maintenance schedule, there is a risk of over-servicing lightly used machines and under-servicing heavily stressed ones.
How to improve preventive maintenance in manufacturing
Here are some tips to follow for effective maintenance in your manufacturing plant.
- Create a detailed record of every machine, including its installation date, operational hours, component life, and past maintenance. Equipment mapping helps you track wear patterns and identify possible failures.
- Use sensors in machines to get updates on vibration, temperature, lubrication levels, and power consumption.
- Have a dedicated space where you can stock spare components. Make sure the spares are categorised, barcoded, and tracked digitally, so that when they reach minimum levels, you can place a reorder instantly.
- Dirt, dust, and oil accumulation are silent killers of machinery. Have isolated cleaning bays within your plant where machines and parts undergo regular deep cleaning without halting production.
- Conduct regular training sessions where your workers can learn about modern maintenance practices, how to handle new diagnostic tools, and how to read sensor data.
Role of insurance in safety
Insurance, especially workmen's compensation policy and engineering insurance, plays an important role in the safety of your employees at the manufacturing plant. They provide financial protection in the event of accidents, injuries, or occupational hazards. Insurance covers medical expenses, disability, and even provides compensation in the event of death, ensuring workers feel safeguarded while performing high-risk tasks.
From the employer’s perspective, insurance not only ensures compliance but also reduces legal liabilities and promotes a safer, more responsible workplace.
Conclusion
Having a preventive maintenance routine in place not only lowers the hefty costs associated with machinery repairs but also improves workplace safety. When you prioritise maintenance, you are building a workplace where safety, accountability, and efficiency go hand in hand. Over time, this mindset creates a ripple effect: workers feel more valued, production lines operate with fewer interruptions, and customers trust the quality of your products.
FAQs
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What are common tasks in preventive maintenance?
When it comes to preventive maintenance, tasks may include cleaning machines, lubricating moving parts, replacing worn-out components, testing safety systems, calibrating equipment, and conducting safety checks to prevent sudden failures.
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Why is preventive maintenance better than reactive maintenance for safety?
In reactive maintenance, machines are only fixed after they have broken down. This can result in a serious accident at the workplace or a production halt. Preventive maintenance ensures problems are caught early.
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What role do employees play in preventive maintenance?
Operators are the ones who first spot unusual sounds, vibrations, or performance issues in the machinery. If they report the same to their supervisor, maintenance teams act quickly to prevent unsafe situations.
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What tools are used for safety checks during preventive maintenance?
Some of the common tools include vibration sensors, infrared thermometers, and oil analysis kits.
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How often should preventive maintenance be done in manufacturing?
The frequency depends on the type of machine, manufacturer’s guidelines, usage levels, and workplace safety standards. It can range from daily checks to monthly or yearly schedules.