Preventive Maintenance (ARC) in Industrial Machinery

Preventive maintenance (ARC) refers to scheduled maintenance activities carried out on equipment or machinery to reduce the risk of unexpected breakdowns.

The benefits of preventative maintenance have led many companies to adopt it as a strategy to reduce long-term costs and minimize the risk of production interruptions. However, what does it take to implement it successfully?

Fundamentals of Preventive Maintenance

Companies that implement preventive maintenance (ARC) do so through a customized plan, which should not be confused with a maintenance manual. This plan details the specific requirements of the organization and the machinery that must be regularly inspected.

So what is preventative maintenance in a nutshell?

To summarize, its main foundations can be listed:

1. It is based on scheduled periodic inspections. Preventive maintenance dates are determined by the condition of the equipment or its use/age.

2. Its goal is to anticipate major breakdowns, identifying and solving small problems before they get worse.

In addition, specific actions are carried out during preventive maintenance activities, such as:

• Replacement of parts.
• Adjusting equipment conditions.
• Restorations to prevent depreciation.
• Inspections to ensure optimal performance.
• Lubrication and cleaning, among others.

Preventive Maintenance Objectives

Through preventive maintenance, the following objectives are sought:

1. Extend the useful life of assets.

2. Avoid unexpected expenses on unforeseen repairs.

3. Detect errors in equipment installation.

4. Reduce production interruptions caused by technical problems.

5. Identify recurring failures.

6. Minimize the risk of injuries and accidents at work.

Especially in companies with heavy machinery, preventive maintenance provides safety for workers and, in many countries, is mandatory.

Advantages and Disadvantages of Preventive Maintenance

Like any type of maintenance, preventive maintenance has its advantages and disadvantages that companies should consider before implementing it.

Advantages:

• Avoid surprise costs for unexpected repairs.
• Reduces overtime costs for maintenance staff, as inspection and repair tasks are scheduled.
• Reduce waste and customer complaints due to delays or quality issues.
• By focusing on extending the life of equipment and ensuring maximum performance, the company can invest less in new machinery and allocate resources to other important areas.
• Allows you to calculate repair costs in advance.
• It is flexible and can be adapted to the needs of both large and small companies, as there are different types of preventive maintenance.

Disadvantages:

• Determining the frequency of preventive maintenance often requires expensive equipment, such as vibration analyzers and other operating sensors or radars, which require initial investment and ongoing maintenance to ensure accurate readings.
• The company must hire or train personnel with advanced technical knowledge to interpret the data provided by this equipment.
• Records of repairs, parts replacements and associated costs must be maintained at each maintenance session.

Maintenance of Specific Components: Engines, Sensors, Pistons and Electronic Panels

In this section, we will cover the maintenance of specific machine components such as motors, stop sensors, pneumatic and hydraulic pistons, electronic panels and other critical elements. These components play a vital role in the operation of machinery and require special care to ensure optimal performance and avoid unexpected problems.

Engine Maintenance:

Motors are the heart of many industrial machines. To maintain their efficiency and durability, the following maintenance activities must be performed:

• Regular inspection of electrical cables, connections and contactors for signs of wear, corrosion or overheating.

• Proper lubrication of bearings and moving parts according to manufacturer specifications.

• Monitoring engine temperature and vibration to identify potential problems.

• Periodic cleaning to prevent the accumulation of dust and dirt that can affect cooling.

Stop Sensor Maintenance:

Stop sensors are critical safety elements on industrial machines. Proper maintenance of these sensors is essential to ensure worker safety and smooth machine operation. Maintenance tasks include:

• Regular verification of sensor functionality by emergency stop testing.

• Visual inspection for physical damage, corrosion or loose connections.

• Immediate replacement of defective or damaged sensors.

• Training of staff in the correct use of stop sensors and in identifying emergency situations.

Maintenance of Pneumatic and Hydraulic Pistons:

Pneumatic and hydraulic pistons are essential components in many industrial machines. Proper maintenance ensures optimal performance and prevents leaks. Maintenance activities include:

• Visual inspection of pistons, seals and connections for air or hydraulic fluid leaks.

• Replacement or repair of worn or damaged seals and gaskets.

• Checking the pressure and adjusting the pneumatic or hydraulic systems according to the manufacturer's specifications.

• Cleaning components to prevent the build-up of dirt and contaminants.

Electronic Panel Maintenance:

Electronic panels control many critical functions on modern machines. Maintaining these panels is vital to ensure trouble-free operation. Maintenance tasks include:

• Visual inspection of electronic components for signs of wear, corrosion or faulty soldering.

• Update software and firmware according to manufacturer recommendations.

• Regular backup of data and programs in case of unexpected failures.

• Training of staff in the proper use of electronic panels and basic troubleshooting.

These are some general guidelines for maintaining critical components on industrial machines. It is important to note that exact specifications and procedures may vary depending on the type of machinery and specific manufacturers. Therefore, it is critical to always consult the manufacturer's recommendations and have trained personnel to carry out these maintenance activities safely and efficiently. Proper maintenance of these components contributes significantly to the reliability and lifespan of machines, as well as improving workplace safety.