Whether it’s a construction, manufacturing, or mining project, downtime is the last thing any business wants. This is because unexpected downtimes come with huge financial losses, a hit in reputation, and can even cause your company to lose business to the intense competition. According to a study done by Vanson Bourne, over 80% of companies have experienced unplanned downtimes over the span of 3 years. On average, those downtimes lasted for 4 hours and cost businesses an average of a whopping $2 million.
In the manufacturing industry, to be specific, heavy machinery is the backbone of the operations. This calls for preventative maintenance as it’s the best way to prevent unexpected downtimes. Proactive maintenance fosters a safe working environment, saves energy consumption, and ascertains better performance and productivity.
That being said, here are some simple and straightforward tips for heavy machinery maintenance:
Document Machinery Use and Monitor the Operations
Machinery wear and tear or breakdown are usually made worse as a result of unskilled handling. Documenting the machinery use and overseeing daily operations will certainly help narrow down where and when the equipment is being used by unskilled workers.
GPS is one of the new and effective ways to monitor large machinery operations. This gadget tracks the movement and records it digitally, and organizes the information for easy retrieval. With such a solution, you can catch problems early and effectively prevent breakdowns.
Lubricate Parts on the Regular
All heavy machinery relies on lubrication for optimum performance. Lubricants are vital as they reduce friction around the moving parts, thus reducing wear and tear. The liquids also help keep the machinery’s interior clean by preventing soot building. Ensure you bear the following in mind:
- Check the level of lubricant regularly. Also, check for oil seal leaks and excessive grease build-up.
- Use the right lubricant amount. Excessive lubrication will result in grease build-up, causing performance issues. On the other hand, using too little runs the risk of increased friction, leading to premature wear and tear.
- Use the lubricant recommended by the manufacturer or the operator’s manual.
Check the Machinery for Wear and Tear
There are many factors that can contribute to machinery wear and tear. These include accidents, subpar operating habits, aging, and environmental factors. Regardless of how many precautions you take, aging will ultimately affect the critical components of the machinery. For example, over time, bolts will bend or stretch out, seals will dry out and crack, and belts will warp. That’s why it’s important to check all the machinery for wear and tear.
In addition to the mechanical components, ensure you assess the electronics and wires as well. Environmental factors like water and dust, vibrations from misaligned belts and gears, and high temperatures from extended use can damage the circuits and wires. Don’t forget to check the alternators, starters, and other electrical components to ascertain the optimum and smooth performance of the machine.
Clean the Machinery Thoroughly
One essential aspect of ascertaining proper lubricant levels is a thorough cleaning. Unfortunately, most operators tend to overlook this step until it’s too late. Dust, dirt, and soot can clog seals, vents, filters, and cooling fans, thus reducing the overall performance. So, ensure you assess every part of your machines carefully.
Pressure washing is the easiest way to clean any heavy machinery. However, there are some components like brass bearings, iron chains, and pins that are hard to clean using a water hose. Also, they contain contaminants like grime and grease, which require special cleaning methods like acid or steam washing and certain cleaning agents.
Train the Workers
As mentioned earlier, lack of operator training is one of the primary causes of machinery wear and tear and even breakdowns. Training the workers is the best way to ascertain your machinery works within the set limits as they learn about the machines in detail. In addition, federal, state, and local laws may require you to hire trained and certified operators to handle a certain kind of heavy machinery.
Ensure all operators know exactly how the equipment works, safety precautions to take during work, and the emergency plan in case something goes wrong. More often than not, employers just provide training during the installation of heavy machinery, and that’s it. They fail to realize that operator training isn’t a one-time thing. Employees come and go, skills become rusty and the machinery may get hardware or software updates over time. That’s why it is imperative to assess and update operators’ skills and knowledge base on a regular basis.
In some situations, the workers may be tempted to skip some safety measures or skimp in order to speed things up, particularly when they are behind schedule. You should never allow them to rush as it increases the chances of mistakes or even fatal accidents. In addition, do not allow the workers to use phones or other distractions while handling heavy machinery.
With these tips, you should be able to stay on top of both your employees’ and machinery’s performance.