Why Preventive Maintenance?
70% of production stoppages are caused by unplanned breakdowns. A Preventive Maintenance (PM) programme identifies these failures before unexpected downtime occurs. Research worldwide shows that a well-implemented PM programme reduces downtime by 25–35%.
Checklist by Maintenance Frequency
Daily Checks (Operator Level)
- Abnormal noise/vibration check on all drive units
- Oil and pneumatic pressure levels
- Photoelectric and inductive sensor cleaning
- Air filter condition
- Closed-loop water cooling system temperature
Weekly Checks (Technician Level)
- Chain and belt tension measurement
- Servo motor and gearbox temperature check
- HMI screen and control panel cleaning
- Vacuum system leak test
- Guide rail lubrication
Monthly Checks (Maintenance Engineer Level)
- Bearing vibration analysis (using vibration measurement device)
- Electrical connection torque check
- Pneumatic cylinder seal replacement (according to operating hours)
- Calibration record updates
- Spare parts stock check
Annual Overhaul (OEM or Authorised Service)
- Bulk replacement of all consumables
- Electrical installation overhaul
- Software and firmware updates
- Performance tests and calibration certification
OEE (Overall Equipment Effectiveness) Tracking
Use the OEE metric to measure machine efficiency:
OEE = Availability × Performance × Quality
World-class OEE is above 85%. Typical targets for packaging lines:
- Availability: 90%+
- Performance: 95%+
- Quality: 99.5%+
Any OEE component falling below target signals that your maintenance programme needs review.
Critical Spare Parts: What to Keep in Stock
Define minimum stock levels for long lead-time parts that cause stoppages:
| Part Group | Recommended Stock | Reason |
|---|---|---|
| Servo drive unit | 1 unit | Lead time 4–8 weeks |
| PLC I/O modules | 2 units | Critical control component |
| Heat sealing band | 1 year's usage | Daily wear item |
| Photoelectric sensors | 5 units | Impact damage risk |
| Main switch / contactors | 2 units | First replaced in electrical faults |
Digital Maintenance Management (CMMS)
Modern facilities manage maintenance operations with CMMS (Computerised Maintenance Management System) software. With CMMS:
- Work orders are created and tracked automatically
- Spare parts consumption is analysed
- Breakdown history is recorded
- Maintenance costs are reported
Dr Mach After-Sales Support
Dr Mach Technology provides comprehensive post-installation service support:
- Remote monitoring: Real-time machine data tracking with early warning
- Operator training: Hands-on training programmes at line side
- Spare parts guarantee: 24-hour supply agreement for critical parts
- Periodic maintenance contracts: Package solutions including annual PM visits
Contact our technical team to optimise your maintenance programme.