Machinery is an essential investment for many industries; it is not uncommon for some organisations to base their entire business model on heavy machinery and electrical systems operating at peak efficiency. Machine downtime can create significant costs for these businesses, both in terms of the outgoings to repair expensive equipment, and in terms of the impact it will have on their productivity and workflow.

In order to avoid this costly downtime, it is crucial to keep machinery functioning correctly at all times. However, even the most well-designed and durable machines will eventually break down if not maintained correctly, which is why proactive, predictive maintenance is the key to extending equipment life and improving its performance.

In this post, we will explore some essential tips to help you establish a routine maintenance schedule that will keep your machine performance at optimal levels, ensuring that your equipment remains useful for as long as possible.

The first step in extending the life of your machinery is to establish a regular maintenance and repair schedule. This should consist of a routine of ongoing inspections, cleaning and repair processes, which will allow you to identify potential issues with your machinery before they become a problem. In this way, you can ensure that any moving parts or components that are subjected to a lot of stress are proactively repaired or replaced before they experience further wear.

A successful preventive maintenance program should include the creation of a detailed log that records all maintenance activities - including inspections, repairs, and part replacements - as and when they take place. By keeping these records up to date, it will be much easier for your whole team to make sure that the proper maintenance procedures are followed, and to make any repairs or take corrective actions as necessary.

If your employees are expected to regularly operate machines in the workplace, it is vital that they are provided with all of the information they need to use and maintain the equipment correctly. Proper operator training will help prevent damage to the machinery, ensure that maintenance tasks are performed safely and correctly, and help operators to catch potential problems before they become major issues.

Operator training should include the provision of a maintenance checklist for machine operators, containing detailed instructions on how to perform everyday maintenance tasks (including safety precautions and recommended tools that need to be employed each time the machinery is used). Much of this information can be found in the relevant operator manuals, but by providing an accessible checklist that uses simple language, it will be easier to ensure that all workers follow these essential preventive maintenance steps.

Finally, it is important that employees and machine operators understand that they are accountable for machinery maintenance. Their responsibilities should be made clear to them, and everyone working within the team should know what is expected of them as part of the predictive maintenance schedule.

Different machinery has different usage requirements, and an effective preventive maintenance program should reflect this. This will depend not only on the configuration of the machinery itself, but also on the conditions and regularity of its usage.

For example, some heavy machinery that is regularly operated for multiple hours a day may require daily maintenance and proactive condition monitoring to make sure it remains fully operational, whereas other pieces may be used less often and therefore only require maintenance every few months. You should also consider whether the machinery is being used in a high-stress environment; equipment that operates at high temperatures, or that is often exposed to dust and moisture, must be checked regularly, whereas machinery operating in a clean environment will likely have lower maintenance costs and requirements.

Scheduling preventive maintenance based on usage will help to extend equipment life, and avoid the costly downtime that comes when a machine breaks, while making the most efficient use of your available resources.

Most expensive equipment will have very specific instructions on how to get the best out of it, and this applies to maintenance just as much as it does to operation. It is vital to carefully consult the operator manuals to make sure these specifications are being followed, and that you train your employees to use the equipment properly.

By consulting this documentation, you will learn any relevant specifications for how the machinery should be set up, stored and looked after, including how often the manufacturer recommends that planned maintenance be carried out. There may also be instructions on specific methods for changing filters, checking fluid levels and carrying out torque checks, which operators will need to know.

It is essential to follow the manufacturer's recommendations to ensure that your equipment is maintained correctly, and that any maintenance steps that are unique to this specific product are understood by the whole team.

Part of following the manufacturer's recommendations is making sure that you only ever use manufacturer-approved components and consumables in conjunction with your machines. Purchasing generic replacement parts might seem like a way to save money, but if these replacements do not offer the right level of product quality, they can cause issues for your systems later down the line.

Similarly, it is vital to invest in quality when sourcing lubricants, including gear oils, hydraulic fluid and greases for large machinery. If the products you purchase are not suitable for your equipment - or simply are not high enough in quality - then it may cause damage to your machine in the longer term, reducing its life expectancy, and increasing the risk of cumulative wear due to poor lubrication.

Organising the right maintenance for your large machinery can be challenging, and require a proactive and careful approach. You must ensure that your equipment is inspected regularly within set specifications, in accordance with a schedule that everyone on site knows and understands; you must also be certain that your operators have all of the tools, products and training they need to service the machine and keep it in good working order.

However, investing in equipment maintenance has its own rewards. By doing so, you can extend the life of your machines, avoid costly repairs and downtime, and achieve maximum efficiency in your production processes. Because large machinery represents an expensive and long-term commitment for any business, it only makes sense to invest properly in maintenance to ensure it can continue to deliver benefits for as long as possible.>/p>

For guidance on choosing the best lubricant product for your application, contact the team at Broughton Lubricants today. Call us on 03300 555 655 to learn more about our industrial and automotive range, or email us at sales@broughtonlubricants.co.uk.