8 Common Machine Maintenance Mistakes and How to Avoid Them

Did you know that factories lose five percent of their productivity, because of downtime?

Machine failure is the leading cause of downtime in the manufacturing business. That’s why it’s super important to keep your machines in pristine condition to sidestep frequent downtimes.

Regular machine maintenance is one thing, but doing it right is another. While you may have the maintenance part down pat, improper machine maintenance has the opposite effect. Unfortunately, most factory professionals are oblivious of machine maintenance mistakes that they make every day.

Today, we’ll be highlighting some of these machine maintenance mistakes that you should avoid at all costs. That way, your machines can remain in tip-top shape and give maximum return on investment.

1. Improper Maintenance Routine

A systematic and elaborate maintenance routine is imperative to the success of your maintenance operations. Not having a proper maintenance routine is one maintenance mistake you can’t afford to make.

Don’t wait for a major machine breakdown to get started on your maintenance efforts. Machine downtime equals a lot of money down the drain. A proper maintenance routine reduces or eliminates machine downtime and ensures maximum profitability.

Predictive maintenance is one maintenance routine you should consider adopting. Predictive maintenance employs data analysis tools and other techniques to detect any machine irregularities. This allows you to fix these anomalies before they spiral out of control and disrupt normal operations.

2. Using Wrong Replacement Parts

It’s normal for people to cut corners when it comes to replacement parts. Replacement parts are expensive, and you can get second-grade ones for almost half the price. They look identical, so why not save yourself some cash by getting knock-off replacement parts?

Using the wrong replacement parts for your machines almost always ends up badly. Instead of addressing the problem, generic parts could exacerbate it. That means you’ll end up paying a lot more for the repairs than buying an original part.

Understandably, it’s possible to buy generic parts unknowingly from a sketchy vendor. As such, you need to be extra careful with where you buy your replacement parts. Only get these parts from a reputable vendor with proper online reviews.

It’s also a good idea to have these parts at hand, before the machines malfunction. That way, you don’t have to stop production while waiting for the replacement parts. Aside from replacement parts, it’s also important to use proper machine maintenance tools when replacing machine parts.

3. Improper Data-Capturing Techniques

Proper machine maintenance is etched in accurate and consistent data capturing. That’s why it’s super important to refine your data collection techniques to reflect the state of your machines. Proper data capture will help you identify any anomalies in your machines and take immediate action

Thankfully, there are tons of data analytic tools to choose from. Liaise with machine operators to find the best one that suits your machines. These data analytic tools should be an integral part of your production and machine maintenance process.

4. Not Encouraging Feedback From Your Technicians

Your technicians know more about your machines than you’ll ever do. Whenever you carry out machine maintenance, encourage suggestions and comments from your technicians. This feedback will be useful in data analysis, policy formulation, and improving factory processes.

Failing to encourage feedback from your technicians is incredibly retrogressive. Let your technician’s feedback be your guiding light when improving machine maintenance.

5. Failing to Document Maintenance Tasks

Documenting maintenance activities is super important for future maintenance operations. Technicians and repair professionals will refer to these documents during subsequent maintenance operations. The documents help make the technicians work a lot easier and less time-consuming.

Enforce a strict documentation policy for any repair or maintenance activity. Ensure complete and accurate documentation with no information gaps. Also, ensure all technicians save their documentation in a central database for seamless access.

6. Overlooking the Manufacturer’s Specifications

There’s a reason why manufacturers include machine specifications with their machines. These specifications ensure you get the most from the machines without overworking them. Choosing to overlook these specifications may work to your detriment.

Exceeding the manufacturer’s specs will accelerate the machine’s wear and tear. This means you’ll have to spend more time and money on repairs and maintenance. Overly Frequent maintenance also translates to a lower machine lifespan.

It’s tempting to ignore the manufacturer’s specs for higher production, but don’t do it. To ensure your machines work at their best, follow the manufacturer’s specs to the letter. Some key specs to keep an eye on include pressure, weight capacities, and electrical input.

7. Using a One-Size-Fits-All Maintenance Plan

Not all machines are built the same; a maintenance plan that works for one machine may not work for another. That’s why it’s best to have a custom maintenance plan for each machine in your factory line. Some machines require minimal maintenance, while others intricate and high-level maintenance.

Adjust your maintenance plans such that delicate machines get the most attention, and sturdy ones get the least. This approach helps minimize machine maintenance costs and facilitates optimum performance.

8. Maintaining Your Machines Too Much

That’s right; there’s such a thing as over-maintenance. The more you maintain your machines, the better they perform, right? Wrong!

Loosening and putting back machine parts too frequently only lowers their lifespan.

Over-maintenance also racks up your maintenance costs and is a waste of technicians’ time. As a rule of thumb, only carry out machine maintenance as per your schedule. The only time you can break this rule is when your machines fail abruptly.

Use the data you collect to schedule your maintenance dates. Stick to these dates, so you don’t wear out your machines with constant maintenance routines.

Say No to These Machine Maintenance Mistakes

You can’t afford to make these machine maintenance mistakes if you want to streamline your production process. You might already be guilty of making the said mistakes already, but it’s not too late to change. Implement the best machine maintenance practices for the greatest effect.

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