maintenance program for milling machine com

milling machine maintenance - machine tool technologies ltd

milling machine maintenance - machine tool technologies ltd

As milling machines are often a core part of a manufacturing process, it is essential they are performing optimally. Our milling machine maintenance services offer a thorough run through, check and repair of any issues the machine tool may be experiencing.

When a milling machine isnt maintained regularly, problems can occur. In some cases milling machine maintenance can be performed by the user, however other aspects require skill and expertise that only specialists possess. This is where Machine Tool Technologies come in. At MTT, our engineers offer unmatched milling machine maintenance services to a range of industrial businesses and manufacturers.

Milling Machine Lubrication There is no denying that a milling machine works hard, which is why it should always be well lubricated. Milling machine lubrication helps to keep the equipment working well and in good condition, as its free to move smoothly. Its not a case of lubricating the machine every day and its not a case of using the first lubricant you find, which is why its often best to seek out professional services. At MTT, we understand that precision is key when maintaining machine tools and can take care of things for you.

Milling Machine Cleaning Its important to keep a milling machine clean, as dirt and debris can build up and cause problems. However, milling machine cleaning isnt an easy task and its best left to those who know what they are doing. Though you may be able to do a basic clean yourself, specialists know how to clean to a professional level.

Regular Milling Machine Servicing A lot of milling machine problems can be avoided with regular maintenance and services, as this often highlights potential problems before they happen. If something small goes wrong with a milling machine and its noticed right away, further problems can occur, and these can be costly. With regular servicing, small problems can be dealt with before they worsen, and you wont be left without a working milling machine.

Nobody wants to be faced with a milling machine that is not working as efficiently as it should, especially not if its a vital part of your production process. This is why a lot of manufacturers come to MTT for milling machine maintenance services.

Regardless of how large or small the problem, or whether you simply want the machine looked over by a professional, you can count on MTT. Throughout our many years of working with milling machines, we have gained a great deal of knowledge and experienced. We know how to service and maintain all types of milling machine to a very high standard.

autonomous maintenance programme for milling machine

autonomous maintenance programme for milling machine

* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

This project is developed as a preliminary study on KONDIA KP-90 Milling Machine located in Institut Kemahiran MARA Jasin, Melaka towards Autonomous Maintenance implementation. This project focus on the first three steps in normal Autonomous Maintenance activities which are included Initial Cleaning, Countermeasure to Abnormalities and Standardization of Problem Solving. Abnormalities of the machine with factors of safety, function and physical were analysed. From the results, dirty abnormalities were happened most and the physical of the machine was most affected by those abnormalities. Most of abnormalities found during this project duration have been tackled; however, there are several abnormalities can not be solved due to various reasons which discussed in this report.

Projek ini dibangunkan bertujuan sebagai kajian permulaan ke arah Program Penjagaan Autonomous untuk Mesin Kisar Menegak KONDIA KP-90 yang terdapat di Institut Kemahiran MARA Jasin, Melaka. Projek ini ditumpukan kepada tiga langkah pertama aktiviti Program Penjagaan Autonomous iaitu Pembersihan Permulaan, Langkah Langkah Mengatasi Kecacatan dan Piawaian Kepada Penyelesaian Masalah. Hampir kesemua kecacatan kecacatan yang berlaku pada mesin telah dapat diatasi. Walau bagaimanapun, terdapat beberapa kecacatan yang tidak dapat diatasi atas beberapa sebab dan dibincangkan selanjutnya di dalam lapuran ini.

To my very sincere and close belated friend, Allahyarham Mr. Affandy bin Zakaria, a staff in Manufacturing Department, IKM Jasin, who has passed away in my final visit of this project.

I also would like to thank all academic staffs in UTeM for teaching me so many things that Ive never been thought before. Also to all staffs in other departments in this university for the cooperation they have given.

5.1 Initial Cleaning ..62 5.1.1 Machine Mapping 63 5.1.2 Definition Of Fuguais...68 5.2 Findings On Initial Cleaning .71 5.3 Results And Analysis 74 5.3.1 Problems In Countermeasure Step ...83

3.11: A Plain Vise (Left) And A Swivel Vise (Right). 44 3.12: Indexing Head And Accessories (Left), And Its Main Features (Right) 45 3.13: The Rotary Table Being Aligned To Its Concentric Axis 46

3.17: (a) An Example Of Tee-slot Cutter; (b) A Tee-slot Being Cut 48 3.18: (a) A Depth Micrometer Being Use; (b) The Female Tee-slot 49 3.19: 5 Grease Points For KONDIA KP-90 Milling Machine Headstock 50

5.1: Five Main Parts Of Vertical Milling Machine From Side View 63 5.2: Five Main Parts Of Vertical Milling Machine From Front View 64 5.3: Parts Configuration For Variable Speed Head Compartment From Side

5.12: Pareto Diagram Of Four Fuguai Classification And Its Percentage 78 5.13: Comparison Between Week 1 And Week 8 Of Fuguai Classification 78 5.14: Overall Results Of Fuguais Category During 8 Weeks 79 5.15: Comparison Of Fuguais Category Trend Along The Project 80

5.2: Typical Broken/Loose Fuguais Found On The Machine 69 5.3: Typical Misplace Fuguais Found On The Machine 70 5.4: Dirty Fuguais, Tools Used, And Results After Cleaning Process 72 5.5: Three Types Of Broken/Loose Fuguais Solutions 73 5.6: Summarized Of Fuguais Found During Eight Weeks Of Visit 75

MI - Maintainability Improvement MP - Maintenance Prevention OEE - Overall Equipment Efficiency OPE - Overall Plant Efficiency PDCA - Plan, Do Check, and Action PM - Preventive Maintenance rpm - round per minute

Production organizations are usually concerned with converting inputs such as raw materials, labor and processes into finished products of higher value at minimum cost satisfying the customer needs. In order to achieve maximum return on investments the production systems will have to minimize plant downtime, increase productivity, improve quality and deliver orders to customers. This has brought the role of maintenance into an important issue (School of Management Studies, IGNOU, 2004).

The increased emphasis on equipment availability, performance, quality, environment conditions and safety considerations has rise up maintenance functions. Total Productive Maintenance (TPM) is a maintenance program which involves a concept for maintaining plants and equipment. TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. According to Venkatesh (2006), the goals of the TPM program is to markedly increase production, to hold emergency and unscheduled maintenance to a minimum, and at the same time, increasing employee morale and job satisfaction.

One of the important factor in TPM is Autonomous Maintenance (AM). This type of maintenance encouraged operator to sense any abnormalities on the machine and maintain common problem by him/herself. By this way, the machine will always be in its idle condition while the operator learns more and feel sense of ownership about the machine.

Milling machines are very useful in manufacturing engineering. Its price is quite high that worth to maintain it rather than to buy a new one. In order to prevent it from deteriorating, correct applications of maintenance works are essential. This type of machines are available in every Manufacturing Department in five Institut Kemahiran MARA (IKM) located in Jasin, Melaka; Pekan, Pahang; Johor Bahru, Johor; Lumut, Perak; and Kampung Pandan, Kuala Lumpur. In each IKM, twelve milling machines are being use by their students. Total of sixty milling machines have costs Majlis Amanah Rakyat (MARA) millions of ringgit.

In order to save the continuous money spending for conventional maintenance, an introduction of AM into Manufacturing Department in IKM has been applied in this project. This type of maintenance familiarizes the operator (student) itself to do routine observations on their machine. By doing this, early detection of abnormalities and major problems are done to reduce parts replacement that will increase maintenance budgets. It also reduce chances of accident happened and reduce the burden of technician works.

This project was planned to develop a pilot activity of AM Program in Manufacturing Department, IKM Jasin, Melaka. A KONDIA Vertical Milling Machine has been selected to be used for this project has been performed from July 2007 to March 2008. A technique called Fuguai Mapping has been used to determine abnormalities on the machine. Group discussion about the machine condition also will be conducted onto students that operated the machine.

Only the AM concepts under Total Productive Maintenance (TPM) will be taken into account for this project. Data gathered were used to analyzed and developed pilot activity of AM Program for the machine. Although there are seven steps of implementing AM, this project will only go through step one to step three as time constraints for other steps to be implemented. The consequence of this project may not be applicable to other projects with different types of machines specifically for the milling machines.

Chapter 4 concludes the research methodology of this project. This chapter discusses the methodology that were use to gather data required to support the development and analysis of the study. This chapter also shows the process planning, flowchart, data gathering method and data analytical technique. Next is Chapter 5 that contains the results and discussions about the development of AM program for KONDIA KP-90 Vertical Milling Machine. Lastly, Chapter 6 provides the recommendations and the conclusion of the whole project.

In general, maintenance can be defined as all activities necessary to keep a system and all of its components in working order (Stephen, 2004). According to Geraerds (1985) maintenance is defined as all activities aimed at keeping an item in, or restoring it to, the physical state considered necessary for the fulfillment of its production function. Maintenance is the action necessary to sustain or restore the machine and equipment up to the performance needed. It includes inspection, overhaul, repair, preservation and replacement of parts. Maintenance also can be defined as the management of avoiding failure.

Maintenance is a combination of science, art and philosophy. Its execution relies on science, art of maintenance depends on individual aptitude and its philosophy should fit to the operation or organization it serves (School of Management Studies, IGNOU, 2004). It is an important factor in product quality and can be used as a strategy for successful competition. Many companies consider maintenance as a necessary activity but increase an expense to the organization and a non-value-added function. More progressive companies view maintenance as a way to reduce costs of producing their product or providing their services. Many companies are using this cost advantage to lower prices and increase their life cycle profits.

The objective of a production department in any manufacturing factory is to achieve a planned output in a specified time. This planned output is normally a function of sales demand. It determines the long term and short term production plans fixing the availability requirements of the factory. At any point of time the condition of machine units of a factory can be represented as one of the following states (Kelly, 1984) :

(a) To enhance overall equipment effectiveness by maximizing availability, performance and quality rates and obtaining maximum return on investments. (b) To extend the useful life of assets by minimizing wear and deterioration. (c) To ensure operational readiness of all equipment at all times and for

In order to achieve world-class performance, more and more companies are undertaking efforts to improve quality and productivity and reduce costs. For more and more companies, part of this effort has included an examination of the activities of the maintenance function. Effective maintenance is critical to many operations. It extends equipment life, improves equipment availability and retains equipment in proper condition. Conversely, poorly maintained equipment may lead to more frequent equipment failures, poor utilization of equipment and delayed production schedules. Misaligned or malfunctioning equipment may result in scrap or products of questionable quality (Swanson, 2001). Finally, poor maintenance may mean more frequent equipment replacement because of shorter life.

According to Moubray (1994), the contribution of maintenance to the performance and profitability of manufacturing systems is to ensure that the plant can perform according to the agreed condition or what the organization expected, by balancing between the allocation of maintenance resources and the plant output.

With the change in manufacturing processes emphasizing lean manufacturing, the reliability and availability of plant are vitally crucial. Poor machine performance, downtime and ineffective plant maintenance lead to the decrease in the profit, loss of market opportunities, loss of production and so on (Wilson, 1999).

Dunn (1996) explained, through his equations, that effective maintenance helps to increase the revenues by increasing the equipment performance and plant capacity, which will in turn maximize the volume of sales. Figure 2.1 below explains the reasons why good maintenance management can maximize the organization profit.

Milling machines are very useful in manufacturing engineering. Its price is quite high that worth to maintain it rather than to buy a new one. In order to prevent it from deteriorating, correct applications of maintenance works are essential. This type of machines are available in every Manufacturing Department in five Institut Kemahiran MARA (IKM) located in Jasin, Melaka; Pekan, Pahang; Johor Bahru, Johor; Lumut, Perak; and Kampung Pandan, Kuala Lumpur. In each IKM, twelve milling machines are being use by their students. Total of sixty milling machines have costs Majlis Amanah Rakyat (MARA) millions of ringgit.

In order to save the continuous money spending for conventional maintenance, an introduction of AM into Manufacturing Department in IKM has been applied in this project. This type of maintenance familiarizes the operator (student) itself to do routine observations on their machine. By doing this, early detection of abnormalities and major problems are done to reduce parts replacement that will increase maintenance budgets. It also reduce chances of accident happened and reduce the burden of technician works.

This project was planned to develop a pilot activity of AM Program in Manufacturing Department, IKM Jasin, Melaka. A KONDIA Vertical Milling Machine has been selected to be used for this project has been performed from July 2007 to March 2008. A technique called Fuguai Mapping has been used to determine abnormalities on the machine. Group discussion about the machine condition also will be conducted onto students that operated the machine.

Only the AM concepts under Total Productive Maintenance (TPM) will be taken into account for this project. Data gathered were used to analyzed and developed pilot activity of AM Program for the machine. Although there are seven steps of implementing AM, this project will only go through step one to step three as time constraints for other steps to be implemented. The consequence of this project may not be applicable to other projects with different types of machines specifically for the milling machines.

Chapter 4 concludes the research methodology of this project. This chapter discusses the methodology that were use to gather data required to support the development and analysis of the study. This chapter also shows the process planning, flowchart, data gathering method and data analytical technique. Next is Chapter 5 that contains the results and discussions about the development of AM program for KONDIA KP-90 Vertical Milling Machine. Lastly, Chapter 6 provides the recommendations and the conclusion of the whole project.

In general, maintenance can be defined as all activities necessary to keep a system and all of its components in working order (Stephen, 2004). According to Geraerds (1985) maintenance is defined as all activities aimed at keeping an item in, or restoring it to, the physical state considered necessary for the fulfillment of its production function. Maintenance is the action necessary to sustain or restore the machine and equipment up to the performance needed. It includes inspection, overhaul, repair, preservation and replacement of parts. Maintenance also can be defined as the management of avoiding failure.

Maintenance is a combination of science, art and philosophy. Its execution relies on science, art of maintenance depends on individual aptitude and its philosophy should fit to the operation or organization it serves (School of Management Studies, IGNOU, 2004). It is an important factor in product quality and can be used as a strategy for successful competition. Many companies consider maintenance as a necessary activity but increase an expense to the organization and a non-value-added function. More progressive companies view maintenance as a way to reduce costs of producing their product or providing their services. Many companies are using this cost advantage to lower prices and increase their life cycle profits.

The objective of a production department in any manufacturing factory is to achieve a planned output in a specified time. This planned output is normally a function of sales demand. It determines the long term and short term production plans fixing the availability requirements of the factory. At any point of time the condition of machine units of a factory can be represented as one of the following states (Kelly, 1984) :

(a) To enhance overall equipment effectiveness by maximizing availability, performance and quality rates and obtaining maximum return on investments. (b) To extend the useful life of assets by minimizing wear and deterioration. (c) To ensure operational readiness of all equipment at all times and for

In order to achieve world-class performance, more and more companies are undertaking efforts to improve quality and productivity and reduce costs. For more and more companies, part of this effort has included an examination of the activities of the maintenance function. Effective maintenance is critical to many operations. It extends equipment life, improves equipment availability and retains equipment in proper condition. Conversely, poorly maintained equipment may lead to more frequent equipment failures, poor utilization of equipment and delayed production schedules. Misaligned or malfunctioning equipment may result in scrap or products of questionable quality (Swanson, 2001). Finally, poor maintenance may mean more frequent equipment replacement because of shorter life.

According to Moubray (1994), the contribution of maintenance to the performance and profitability of manufacturing systems is to ensure that the plant can perform according to the agreed condition or what the organization expected, by balancing between the allocation of maintenance resources and the plant output.

With the change in manufacturing processes emphasizing lean manufacturing, the reliability and availability of plant are vitally crucial. Poor machine performance, downtime and ineffective plant maintenance lead to the decrease in the profit, loss of market opportunities, loss of production and so on (Wilson, 1999).

Dunn (1996) explained, through his equations, that effective maintenance helps to increase the revenues by increasing the equipment performance and plant capacity, which will in turn maximize the volume of sales. Figure 2.1 below explains the reasons why good maintenance management can maximize the organization profit.

best practices for milling machine maintenance - the werks c & c

best practices for milling machine maintenance - the werks c & c

Milling machines are some of the sturdiest machines out there. The main function of these machine tools is to remove material from a work piece, often for functionality purposes. In fact, pavement milling machines have the ability to remove over one foot of asphalt while still continuing on to perform other tasks.

In order to keep these hard-working machines in tip-top shape, there are a few things that can be done. Some of these maintenance tasks can be performed by machine shop staff, while other tasks can be performed by you, the machine owner. Below, well look at just a few things you need to keep in mind to properly maintain milling machines.

One way to keep tools for machine services in good condition is by making sure that they are adequately lubricated. In order for machines to work properly, they must have the proper lubrication that allows all parts to move smoothly. But before you start lubricating your milling machine every five minutes, make sure youre 100% aware of how often you should be lubricating and how much lubricant you need to be using. Precision is key when maintaining machine tools!

Another requirement for keeping a piece of machinery usable is making sure that is properly cleaned after use. Many machine parts are often exposed to dirt and other contamination, so its crucial to keep your machine clean to prevent any problems. If youre having any issues with operating your milling machine, dirt could be the culprit! If youre unsure where to look or you think your machine could use a professional cleaning, take your machine to a machine shop. There, machine shop employees will be able to provide a thorough cleaning and help prevent any problems from occurring in the future. In addition, they can provide machine tool repair services if you find that some part of your machine needs repair or replacement. Rebuilding tools certainly isnt an expense you should be paying often, so its a good idea to try and fix a small issue before it takes a toll on your machines.

By keeping up with daily inspections, you can prevent a problem from happening right from the get-go. This is especially important if youre using your milling machine on a daily basis. If something is amiss and you start using your machine without thoroughly inspecting it first, you may be in for a world of trouble. If something looks fine one day and operates wrong the next, an inspection can catch the issue before its too late.

If you find any problem with your tool but are unsure of how to fix it, reach out to your machine shop immediately for the fix or other tips. But until then, make sure youre practicing good maintenance with all of your machine tools.

daily maintenance and maintenance of cnc milling machine - news - shandong alles energy technology co.,ltd

daily maintenance and maintenance of cnc milling machine - news - shandong alles energy technology co.,ltd

The CNC milling and machining center is an advanced equipment that integrates machine, electricity, and hydraulics into a single, high automation process, complicated structure, and high price. In order to fully realize its benefits, it is necessary to do regular maintenance and maintenance work. The CNC system has fewer failures, that is, it tries to improve the average time between failures of the system. The main maintenance and maintenance work has the following contents:

(1) The CNC milling and machining center operators should be familiar with the machinery, numerical control device, hydraulic pressure, pneumatics, etc. of the equipment used and the specified use environment (processing conditions), etc., and must strictly follow the requirements of the machine tool and the numerical control system instruction manual. Reasonable use, try to avoid failure due to improper operation. For example, for the operator, he must understand the stroke size of the machine, the spindle speed range, the power of the spindle drive motor, the size of the table, the size of the table load capacity, the speed of the motorized feed, the maximum tool size allowed by ATC, and the maximum Tool weight and so on.

(2) Before operation, it must be confirmed whether the spindle lubricant and the guide rail lubricant meet the requirements. If the lubricant is insufficient, add the appropriate lubricant according to the required grade and model. At the same time, make sure that the air pressure is normal.

(3) Air filter cleaning. If too much dust accumulates in the air filter of the digital control device M, the cooling air in the cabinet will be blocked and the temperature in the cabinet will be too high, making the system unable to work. Therefore, you should regularly check the cleaning according to the surrounding environment. When there are dust and oil on circuit boards and electrical components in electrical cabinets, they should also be cleaned in time.

(5) Replace the memory battery regularly. Part program, partial S data and system parameters exist in the CMOS memory of the control unit. The contents of the current bit M of the separate absolute pulse encoder are kept by the battery during shutdown. When the battery voltage drops to a certain value, it may be Loss of parameters. Therefore, check the battery voltage regularly. When replacing the battery, it must be done while the CNC is powered on.

(6) Long-term maintenance of CNC machine tools that are not used. When the CNC system is not used for a long period of time, the CNC system should always be powered on. When the machine tool is locked, it can be run empty. In the rainy season, the air should be powered up every day, and the electrical components themselves should be used to generate heat to drive away the moisture in the CNC cabinet to ensure the stable and reliable performance of electronic components.

1. After the end of each shift, the operator shall clean the chips and grease scattered on the workbench, guide rails, etc. Before the work is completed, the servo axes shall be stopped after returning to the origin;

CNC milling machine is a kind of precise equipment. Only by insisting on the daily maintenance of small CNC machine tools can we extend the service life of components, prolong the wear cycle of mechanical components, prevent accidental and vicious accidents, and strive for long machine tools. Stable time. Therefore, the operation of the CNC milling machine must be done in three stages (definite, fixed, fixed); the operator must be professionally trained and skilled in operation, non-professionals must not move; before the operation must be confirmed that everything is normal, then re-installed Workpieces.

mill maintenance methods | | miller magazine

mill maintenance methods | | miller magazine

Maintenance, repair and technical service are significant since they affect lifetime of milling machines and ensure them to work non-stop at desired levels. If regular and good maintenance is not performed, machines cannot work for long years. Predictive maintenance monitors active machines and equipment in order to detect possible breakdowns. Thus, it prevents downtimes for machines because of unplanned maintenance as well as loss of production and unnecessary part replacements. As a result, maintenance time and downtime stemming from breakdowns decrease up to %25-30. It enables eliminating minor flaws before letting them to evolve into more serious problems.

Long time ago, mills were giving a break for production at weekends and maintenance teams were performing their duties until noon on Mondays to allow the mill to be back into action. Now most mills are active 7 days and 24 hours. The downs for maintenance are now at least every 10 weeks. Maintenance can be defined as all kinds of activities like repairs, replacements, inspections etc. in order to maintain working of buildings and equipment during their desired life expectancy.

Maintenance, repair and technical service are significant since they affect lifetime of milling machines and ensure them to work non-stop at desired levels. If regular and good maintenance is not performed, machines cannot work for long years. Regular maintenance is one of the most important factors that affect product quality. Regular maintenance prevents downtimes for machines because of unplanned maintenance and it enables to decrease costly part replacements and dependency to third party repairers.

INSUFFICIENT MAINTENANCE Insufficient maintenance results in shutdowns for the mill and causes a decrease in capacity and inadequate production. Accelerated amortizations for machines, increase in mineral oils and product costs are also among results of insufficient maintenance. And the ultimate results may be loss of prestige and bankruptcy because of poor quality products.

Expenditures on maintenance cannot show direct returns, but they are very important for guaranteeing the overall return from the operation. Small amounts of costs for maintenance can prevent the mill from far reaching breakdowns and a huge financial damage. Besides, regular maintenance on machines also decrease spare part and service costs. We can diagnose many problems in the mill at early stages thanks to maintenance. One of the first things to examine when a mill is experiencing poor results is the maintenance.

MAINTENANCE METHODS Adequate maintenance program can be achieved by the use of three different methods: Unscheduled maintenance, preventive maintenance and predictive maintenance (Fig. 1). Management and inspectors, can choose and arrange maintenance systems according to specific needs and local conditions by making use of those methods.

2-SCHEDULED MAINTENANCE The aim of Planned or Preventive maintenance is to minimize the need for emergency maintenance. It is performed by either one of the following sub-methods: Periodical Maintenance (Preventive Maintenance) Predictive Maintenance

A-Periodical Maintenance (Preventive Maintenance) The aim of this method is to prevent components of machines or equipment from failures and to improve their strength before any breakdowns. All components of machines or equipment are regularly monitored and failures or possible failure sources are determined and eliminated.

In order to perform the periodic maintenance, a maintenance schedule consisting of check lists is prepared. The maintenance schedule is prepared and kept by the engineer responsible from the maintenance. But it is performed by mainteFig 1. Maintenance Methods nance technicians.

Periodic maintenance includes four main group of activities for component of equipment: cleaning adjusting (e.g. belt tension), replacing (e.g. oil, filters etc. ) inspection and examination. (Please refer sources at the end of the article for further information about necessary factors to take into consideration for periodic maintenance.)

b- Predictive Maintenance This is a relatively new approach as a result of latest technological developments. This concept was first introduced in Turkey in 1988 by R. Kubilay Kse at Middle East Technical Universitys National Machine Design and Manufacturing Congress. He chose to use the term Kestirimci Bakm for Predictive Maintenance.

When performing predictive maintenance, some of the parameters are measured when machines and equipment are still working. Some measuring devices are used for this. Results are recorded at a specific time interval and results are evaluated according to some statistical methods and tendency analysis. Results show some information about machines and equipment. Changes in those results are tracked and possible defects at machines and equipment may be detected before they actually occur and maintenance can be performed on those machines accurately and adequately. In short, predictive maintenance is based on the performance of the machine.

This method enables to monitor machines or equipment in order to detect possible breakdowns. As a result, unscheduled shutdown of machines and equipment, loss of production and unnecessary part replacements are minimized.

Advantages of Predictive Maintenance Expected life time and productivity of equipment increases Enables corrective maintenance for critical components. Machines that are in good condition are not stopped unnecessarily and this saves time. Maintenance time and downtime for machine breakdowns decrease 25-30%. Work-load and labor costs decrease. Maintenance costs decrease significantly. It is 8-12% more profitable than preventive maintenance. More energy saving. Prevents minor flaws to become source of bigger problems in time. Possibility of significant breakdowns on machines decrease to the lowest level. Production loss decreases considerably. Production levels go up by 20-25% Breakdowns decrease by 35-45%.

PREDICTIVE MAINTENANCE PHASES 1. Measurement: Critical points to be analyzed and measured are identified. Necessary measurements are performed during working conditions of the machine. Predictive maintenance usually involves non-destructive tests like oil analysis, temperature analysis (infrared thermography measurement), ultrasonic test, vibration measurement and visual inspection. 2. Analysis: Results of measurements are analyzed. The source of the failure is analyzed. 3. Repair: The detected fault is evaluated according to working schedule of the mill and necessary repair works are done.

Maintenance leader maybe a mechanical engineer or another qualified technician who studied engineering or technical disciplines. Maintenance must be performed by well trained personnel who have technical knowledge. This training will also include safety issues and detailed information about special machines.

If we do not have enough personnel that have necessary and adequate technical experience or if we need machines to work more efficient, we have to seek technical support from manufacturer of machine or equipment to perform maintenance. This can be done with service contracts.So that, manufacturers will replace failed parts with original and high quality ones and warrant coverage will continue.

Personnel at the production floor are at the first level of maintenance. Maintenance workers on the spot are the second level of maintenance, and equipment engineers constitute the third level of maintenance.

Predictive maintenance is generally performed by a contracted or expert technician. Predictive maintenance team must be qualified and well trained about cutting edge technology. They must have measurement devices and know how to use them. And they must also know how to analyze data from former measurements and report them properly.

ORGANIZING MAINTENANCE ACTIVITIES In order to evaluate equipment which maintenance was performed on, maintenance schedule and an inspection schedule are needed. Maintenance schedule has to be planned by maintenance leader in cooperation with management and he/she should complete a number of arrangements before maintenance program takes effect.

Responsible technicians have to draft a form for each machine and equipment of the mill. The forms have to include following information: Name of the machine Code of the machine Location Year of production Name of manufacturer Capacity Mechanical drawing Power of engines Serial number List of spare parts Supply source

Past maintenance activities and maintenance specifications from manufacturers must also be recorded and loaded into maintenance programs. All catalogues, maintenance and repair manuals, spare part catalogues etc. must be asked from manufacturers. This procedure must be performed for every machine at the plant.

Production manager of the mill must keep records of inspection results and part replacement during repair works. He/she must prepare timetables for preventive maintenance tasks. Maintenance leader must continuously track equipment conditions as part of decision process. This enables to change maintenance programs when it is feasible to do so.

CRITICAL SPARE PARTS MUST BE IN STOCKS It is important for the mill to have critical spare parts available in stocks against possible failures. Giving order for a spare part and stopping the whole shift will cause important losses for the plant. Millers should not evaluate critical stocks as a financial burden for them.

Spare part inventory of the mill may change according to maintenance activities in the mill. The management should decide on the components and their amount to stock. To do so they evaluate the location of the mill and they compare logistics cost and stock cost. Spare parts inventory must be tracked closely by management of the mill by means of a computer program.

COMPUTER ASSISTED MAINTENANCE MANAGEMENT SOFTWARE Records should be kept well for a reliable maintenance program. Newly developed software (Computerized Maintenance Management System CMMS) support record keeping, scheduling and cost control tasks significantly. Many software packages involve various interactive modules that share a common database. Each module is assigned to a specific maintenance task like preventive maintenance, inventory control, work orders, procurement, equipment history, job scheduling, backup schedule, human resources planning, budgeting, cost control etc. Maintenance software are designed to run on desktop or laptop computers.

Can you help me locate a manual for the Natasha Posho Mill, a small, one-person operated non-electric model? A family is operating one, but with cover, the amount of milling being done is minimal. Yet they thing they must have it maintained every 2 months. I would like to get an actual hours of operation to maintenance ratio. Thank you so much.

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