Large industrial plants lose millions of dollars a year because of machine failures. Siemens’ True Cost Of Downtime 2022 report suggests that unplanned downtime costs Fortune Global 500 companies nearly $1.5 trillion, or 11% of their annual revenue. This figure is almost 1/3 of the GDP of India!
More shockingly, hardware failures account for 45% of all downtime. This highlights the importance of a robust hardware infrastructure and its maintenance. Hence, regular machine maintenance is a top priority for all businesses globally.
Therefore, we share 7 simple machine maintenance checklists to cut unplanned downtime. Before we proceed with the checklist, it is crucial to understand the various types of maintenance.
9 Types of Machine Maintenance
Nine types of machine maintenance can be mixed and matched to create a well-balanced maintenance strategy.
Corrective Maintenance
It involves any work undertaken to fix a problem before it causes a complete failure. It is most commonly associated with smaller, non-invasive tasks that fix a problem and get assets back into proper working order. We can schedule a corrective repair for an upcoming routine maintenance visit.
Condition-based Maintenance
When we observe a decline in machine performance, we employ condition-based maintenance to identify and rectify potential issues. Therefore, it relies on monitoring the actual condition of assets. Inspection, performance data, or periodically performed tests help assess and improve efficiency and machine life.
Routine Maintenance
Routine maintenance is the basic one that includes checking, testing, lubricating, and replacing worn or damaged spare parts.
Reactive Maintenance
We do reactive maintenance when a machine breaks down and needs to be fixed as quickly as possible. It is called ‘fighting with fire’ because of the unexpected breakdown of a machine, which usually requires emergency repairs.
Run-to-fail Maintenance
Run-to-fail maintenance is like reactive maintenance because it involves running equipment until it fails. However, run-to-fail is a conscious decision, whereas reactive maintenance is not. In addition, plans are made to ensure that parts and labour are available to repair or replace the equipment as soon as possible.
Preventive Maintenance
Preventive maintenance is regular maintenance to keep machines working properly. There are two main types: time-based and usage-based.
Time-based preventive maintenance is scheduled at specified intervals, such as the last day of the month. Usage-based preventive maintenance is when work is scheduled based on the operation of the equipment, for example, after 10 production cycles.
Predictive Maintenance
Predictive maintenance uses tools and sensors to monitor machine performance in real-time. This allows potential problems to be identified so they can be rectified before failure occurs.
Prescriptive Maintenance
Prescriptive maintenance further automates the maintenance process through machine learning (ML) and artificial intelligence (AI). The ML and AI-based sensors track machine performance in real-time, giving you insight into what maintenance needs to be done and when.
7 Machine Maintenance Checklists
70% of companies acknowledge that they are unaware of equipment that requires upgrading or replacement. This translates into a lack of preventive maintenance as the primary cause of unplanned downtime. So, to avoid breakdowns, companies should have:
- A backup plan,
- Perform routine tests,
- Monitor systems properly,
- Inform their team about downtime emergencies, and
- Prepare a strategic checklist for breakdown scenarios.
To help with this, we have prepared a list of machine maintenance checklists that can be useful in maintaining your equipment. Here we go!
1. Pass-or-Fail Checklist:
As the name implies, a pass/fail checklist simply identifies whether the condition of a machine is ideal or not. This type of checklist is optimal for measuring the condition of a machine as it has a binary choice of good or bad.
For example, if a company has machine X, they can:
- Record the strokes-per-minute rate at which Machine X is operating. Is Machine-X’s inlet temperature less than 70 °F? (Yes/Pass, No/Fail)
- Record the product’s outlet temperature from Machine X using the infrared temperature meter. Is the outlet temperature less than 95°F? (Yes/Success, No/Fail)
If you mark any task as ‘No/Fail,’ notify the machine maintenance technician or create a work request in your equipment management software.
2. Step-by-Step Checklist:
Step-by-step checklists are ideal for tasks requiring more than equipment monitoring. They are especially effective for preventive maintenance procedures involving the replacement of belts, motors or other equipment components. The checklist also provides detailed instructions for each step, ensuring that each technician follows the same procedure and completes all required steps. For example, a machine maintenance technician might:
- Lockout from the main panel to complete the preventive maintenance task.
- Test the machine to ensure the lockout effectively prevents it from running.
- Remove the conveyor belting, replace non-drive side bearings, and inspect the shaft for damage.
- Install conveyor belting and test the conveyor at specified speeds.
3. Safety Checklist:
Safety should always be a priority when operating machinery. Whether it is machinery in good working order or a machine under maintenance, implementing proper safety measures is critical for worker safety and smooth production. It also helps you produce accurate reports for audits and regulatory requirements. Machine safety practices should, include:
- Check inventory and restock all first aid kits.
- Check eye wash bottles, safety signs and equipment labels.
- Inspect for exposed moving parts (chains, belts, gears, and flywheels.).
- Change batteries in safety equipment such as smoke detectors and flashlights.
4. Fluids and Fuels Checklist:
The fluids or lubricants are crucial for machinery maintenance, to keep them running smoothly. Efficient lubrication can improve the life of a machine while reducing the need for maintenance. In addition, fuel is one of the biggest expenses for a company. So, It is a good idea to create a checklist to keep track of fluid and fuel consumption that may cover:
- Regularly check for engine oil, hydraulic oil, transmission fluid, and engine coolant levels.
- Considering fluid analysis for deeper insights into equipment health.
- Ensuring the proper functioning of petrol, diesel, and propane fuel delivery systems.
5. Control Through KPIs
Next, it is beneficial to set measurable objectives (KPIs) against which you can evaluate the success of your preventive maintenance programme. Some valuable metrics to track include:
- Total downtime and breakdowns.
- Total machine maintenance costs.
- Equipment lifespan and replacements.
- Efficiency levels of machines.
Because the more you can measure, the more you can add value to your machine maintenance.
6. Bucket Essential Maintenance Tasks
For each piece of heavy equipment, find out what maintenance is required and how often it should be carried out. You can often find this information in the equipment manual or by contacting the manufacturer. Make a bucket of tasks, such as:
- Inspecting critical components such as hydraulic systems, brakes, steering, and electrical systems for wear, leaks, or damage.
- Hydraulic system maintenance which includes checking for leaks, monitoring fluid levels, and testing the system’s functionality.
- Structural integrity checks, such as checking the frame for cracks or structural damage and ensuring that all guards are securely in place.
7. Standards and Regulations-based Checklist:
Most facilities need to meet strict health and safety requirements. In some cases, complying with regulations means keeping certain equipment in good working order. Central and state regulations may require specific maintenance tasks and procedures. You will need to take these into account when creating your preventive maintenance checklist:
- Only trained professionals should be responsible for maintaining records and for making changes to programmable electronic systems.
- Control switches should be clearly marked, and emergency stop controls such as mushroom-head push buttons should be easily accessible.
- Only authorised and trained personnel should operate machinery, paying particular attention to new starters, young workers and those with disabilities.
- Regular maintenance is essential to ensure machine reliability, prevent breakdowns, and reduce the risks associated with faulty equipment.
- Implement a preventive maintenance checklist that includes regular fluid checks and changes, lubrication, filter changes and belt/hose inspections.
Comply with other international standards for electrical, electronic and related technologies issued by the International Electrotechnical Commission (IEC).
Equipment Management Software to Keep Your Machines in Premium Condition
Preventive maintenance is crucial to reducing unplanned downtime. Implementing a robust preventive maintenance program with Equipment Management Software can help slash reactive maintenance by over 67%.
Therefore, look for a tool that helps you create checklists, assign tasks, track results and generate reports easily. To help with preventive maintenance checklists, NYGGS offers an equipment software tool that provides many benefits, including:
- Makes organising and tracking maintenance activities easier and analyses results over time.
- Create, distribute and maintain digital checklists for your maintenance tasks.
- Helps manage spare parts inventory to ensure smooth supply when needed.
- Creates step-by-step instructions with visuals, making it easier for maintenance teams to understand and follow procedures.
- Records and tracks any anomalies or issues, ensuring that nothing is overlooked and any potential problems are identified and dealt with promptly.
So what are you waiting for? Go digital with your machine maintenance checklist with NYGGS. Contact us to learn more!