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A lack of preventive maintenance could be costing you more than you think. According to recent research by Siemens1 unplanned manufacturing downtime now costs Fortune 500 companies almost €1.4 trillion, equivalent to 11% of their annual turnover.
The problem doesn’t just affect big business. Inflation and higher productivity rates mean the average cost of a lost manufacturing hour has risen 50% across industries compared to 2020. This article examines why it is time to switch from reactive to proactive maintenance by adopting scheduled parts cleaning and repair based around automatic parts washers.
‘Reactive’ or ‘run to failure’ maintenance addresses problems after they occur. Operators will deliberately leave equipment running without maintenance until it breaks down. This can cause expensive downtime, lower productivity and often higher repair or replacement costs.
Run to failure is still used by 52% of manufacturers, but it is being quickly replaced by predictive and preventive maintenance.2
Planned Preventive maintenance (PPM) is a proactive approach to equipment care. It involves routine inspections, cleaning, parts replacement, and performance monitoring. This prevents unexpected machine breakdowns and extends their lifespan.
Preventive maintenance (also referred to as preventative maintenance) are terms for the same thing, and both are commonly used. An alternative term is ‘scheduled maintenance’.
A well-implemented PPM schedule offers several significant advantages:
Preventive maintenance involves several core elements that together create a comprehensive maintenance strategy. Here’s a breakdown of essential activities.
Scheduled inspections are crucial as they allow technicians to spot worn-out parts or leaks before they result in machine breakdowns. According to research, the average facility spends 33 hours each week on scheduled maintenance, up from 20 hours over 2020 data.3
Over time, dust, debris, and oil build-up can affect performance, reduce efficiency, and lead to overheating. Regular cleaning not only extends equipment lifespan but also contributes to a safer work environment. Parts cleaning is a critical step in removing harmful contaminants from components. It reduces friction and wear, helping maintain peak operational efficiency.
During inspections, technicians may identify parts that are worn and nearing the end of their useful life. Proactively replacing these parts can prevent a minor issue from escalating into a major repair.
Monitoring key performance indicators (KPIs) for each machine is essential for a well-functioning PPM. By tracking metrics like operating speed, vibration levels, and temperature, technicians can identify early signs of potential issues.
A preventive maintenance schedule must be tailored to your plant’s unique equipment and operating conditions, but it should always include the following steps:
Safetykleen offers a full-service parts cleaning solution, including machine rental, chemistries, waste removal, servicing and support. As a trusted partner, Safetykleen understands the value of extending the lifespan of your manufacturing machinery through regular scheduled cleaning.
Contact us if you’d like support in optimising your parts cleaning. Our team are available for a free site survey and tailored advice.
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