Preventive Maintenance. Machine Tool Service Inc.

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Marian Hudson
5 years ago
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1 Preventive Maintenance Machine Tool Service Inc.

2 What is Preventive Maintenance? A schedule of planned maintenance actions aimed at preventing unscheduled equipment down time. It is traditionally based on elapsed calendar time or fixed unit count usage. o Predominantly time and/or usage based o Typical periodicities: Daily, weekly, monthly, quarterly, semiannually, annually, and bi-annually o Customizable conditions-based maintenance o Tracked using a computerized maintenance management system (CMMS)

3 Maximize Availability Why Preventive Maintenance? o Maximize equipment availability o Minimize downtime o Use technicians efficiently Minimize Cost o Improved equipment reliability o Breakdown prevention o Reduce unscheduled interrupted or postponed assignments

tolerances or dimensions, and shortened tool life Often Metal chips and fines from cutting and grinding processes consolidate in the coolant sump causing microbial growth on the bottoms of

4 Why Change Coolant? As coolant is used in a machine it becomes contaminated by oils, dirt, metal chips and other foreign debris. This contamination can have adverse effects on the machine, such as: o Rusty parts, shortened sump life, excessive foaming, discoloration, excessive bacterial growth, problems holding part tolerances or dimensions, and shortened tool life Often Metal chips and fines from cutting and grinding processes consolidate in the coolant sump causing microbial growth on the bottoms of coolant tanks By changing your coolant on a periodic basis, you will remove contaminants from your machines thereby decreasing the breakdown of the machine, tools, and tanks that result from ineffective coolant Bacteria and rust build ups due to poor coolant management

5 What is Predictive Maintenance? A maintenance technique that uses data from equipment and other relevant tools. These data allow events and trends in performance and equipment settings to be monitored through advanced analysis techniques and failure behavior profile matching. Analysis of component performance data and other indicators enable the identification, give warning, and prioritize impending or imminent unscheduled failures in advance. Predictive maintenance is complementary to condition-based preventive maintenance.

6 What are my Options? Tailored Preventive Maintenance Programs o Choose which machines o Choose periodicity - daily, weekly, monthly, quarterly, semiannually, annually, bi-annually o Analyze possibilities for conditions-based maintenance schedules based on machine history and environmental shop conditions Coolant Changes o Choose periodicity - quarterly, semi-annually, annually Predictive Maintenance o Spindle clamping pressure o Power supply readings o Calibrations o Alignments *MTS offers the periodicities in bold font

7 What MTS does for You MTS will develop a tailored preventive/predictive maintenance plan for each machine based on the manufacturer s recommendations and the customer s needs MTS manages maintenance schedules with a computerized maintenance management system (CMMS) - MaitenancePro MTS will schedule maintenance with the customer to minimize machine down time and maximize customer efficiency MTS will make recommendations on observations made during the maintenance MTS will maintain historical records of all maintenance conducted and will provide those records to the customer MTS will eliminate stress by tracking schedules, conducting machine maintenance, and keeping all historical records

8 Customer Expectations Fluid acquisition and disposal is the responsibility of the customer (MTS will alert 30 days prior to conducting PM) Replacement oil filters and batteries are the responsibility of the customer (MTS will alert 30 days prior to conducting PM) Findings of PM inspections could indicate required corrections charged at MTS hourly rate (options provided for customer s decisions no additional charges will be applied without the customer s explicit consent)

Our PM Documentation Information filled in by the technician conducting PM Work Order #: 15030 Date Issued: Date Completed: Completed By: Actions Recommended?

Unique Machine Name 123456 Customer and machine identification information Type of PM conducted Notes/ recommendations from technician conducting PM Preventive Maintenance Annual Inspection **Follow

9 Our PM Documentation Information filled in by the technician conducting PM Work Order #: Date Issued: Date Completed: Completed By: Actions Recommended? Assignment 1/16/2015 No / Yes (Recommendations in notes section) Customer: Machine ID: Make: Model: Serial #: Type: "A" Miyano BNC 34C BN32521C Lathe Asset Info Your Reimel Company Machine Your Unique Machine Name Customer and machine identification information Type of PM conducted Notes/ recommendations from technician conducting PM Preventive Maintenance Annual Inspection **Follow all MTS Lock-out/Tag-out procedures** ( ) Clean chips from chuck unit ( ) Check for smooth chucking and unchucking ( ) Check tension of synchro belt ( ) Check for wear of synchro belt ( ) Check tension of spindle v-belt ( ) Check for wear of spindle v-belt ( ) Check way lube tank and refill if necessary ( ) Clean strainers in hydraulic tank ( ) Replace hydraulic oil with 10 gal. of Choice 32 (or eqiuvalent) ( ) Check for oil leakage and damaged hydraulic piping ( ) Check electrical components for dirt and discoloration ( )Check slideway covers and wipers for wear ( ) Clean all cooling fans Type 12M PM procedures completed by technician Technician Notes: Signature of technician conducting PM Signature: Date: *** End Work Order # *** 15030

10 Our Pricing Structure Semi-annual/Annual/Bi-annual PMs: o Machines with hydraulic reservoir: $300 per machine per PM plus travel If monthly PMs completed by MTS: $275 per machine o Machines without hydraulic reservoir (i.e. most Haas and Fadal): $200 per machine per PM plus travel If monthly PMs completed by MTS: $175 per machine o Approx. 3.5 hrs downtime per PM Quarterly: Equipment Dependent (not common) Monthly PMs: $35 per machine per month plus travel o Typically no machine downtime o 11 month plan, 12th monthly PM will be combined with annual PM Coolant Changes: o <50 gal. coolant tank: $200 per machine per change plus travel o gal. coolant tank: $300 per machine per change plus travel o >150 gal. coolant tank: $400 per machine per change plus travel o Full tank removal (for tank repair): additional $400 minimum o Downtime is machine dependent

11 Questions?

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Proper Tube Mill Coolant Best Practices and Running a Profitable Mill Presented By Steve Lowery Tower Oil & Technology Co. Tube Producing Conference September 23 rd 2013 TUBE MILL CONSIDERATIONS Evaluation