How to reduce faults and downtime in your production
Downtime and faults in the production process can be costly, but fortunately you can reduce the risk by introducing simple routines in your day-to-day operations. In this article, we share our tips on how to avoid unplanned downtime.
1.
Monitor your machines regularly
When it comes down to it, unplanned downtime is rarely as sudden as it seems. It is often the sum of a number of factors that you can detect by monitoring your machines or through ongoing maintenance. That is why it is important to check the condition of your machines regularly. Wear and leaking seals may not be an acute problem, but if you do not keep an eye on their condition, they can develop into downtime.
2.
Use colour coding
The properties of different lubricants vary considerably, and filling up with the wrong one can cost you dearly in downtime. On a busy working day, when lubricants may not be at the top of the agenda, it can be difficult to tell one product name from another.
That is why we recommend colour coding your equipment and your oils. Mark on the equipment which lubricant should be used, for example red for hydraulic oil, green for gear oil and so on. Create a system for your lubricants and make it as easy as possible for everyone who maintains the equipment to fill up with the right lubricant.
3.
Listen for unusual noises and vibrations
Unusual noises or vibrations can indicate poor operating conditions and, in the worst case, develop into downtime. So keep an eye out for abnormal noises or more vibration than usual from your machines. It can be a good idea to use vibration monitoring equipment to keep track of the condition of your machines. Vibration monitoring makes it possible to predict faults at a very early stage.
Machines change over time, and so do their vibrations, which is why it is important to monitor the condition of each machine continuously.
4.
Check the temperature
Checking the oil temperature regularly is important for minimising faults and downtime. If the oil is too hot or too cold, it may indicate that something is wrong. Your equipment will not perform optimally if the oil temperature is too high or too low. We therefore recommend making temperature measurement part of your routine.
Start by determining what the optimal operating temperature is. Then set up a routine for measuring and recording the oil temperature, so you can follow how it develops.
5.
Check the oil for foam
Too much foam in your lubricating oil can indicate several things, from a leaking pump to an incorrect oil level. Whatever the cause, it is a sign that something in the machinery is not as it should be, and that can cost you dearly in performance.
We therefore recommend checking the oil regularly, for example through the machine's sight glass. This lets you see whether there is more foam than normal, and in general you will be able to spot any changes in the condition of the oil. Is the oil darker than usual, for example? You should react to any change in the oil.
6.
Have an oil analysis carried out
Unfortunately, not every change in the oil, or in the machine, can be seen with the naked eye. That is why we recommend having oil analyses carried out on a regular basis. An oil analysis can reveal damage before it occurs and give you an overview of the machine's condition. Based on the results, you can take action before it ends in a breakdown.
We can analyse your oil samples at our own laboratory in Denmark. Our oil analyses cover all industries and help ensure stable and safe operation. Contact our customer service team if you would like to hear more about the options.