Guide on Preventive Maintenance vs. Corrective Maintenance

Introduction

Maintenance is a crucial function for ensuring the proper functioning and longevity of equipment. This guide provides a comprehensive overview of the two main approaches to maintenance: preventive maintenance and corrective maintenance. We will explore in detail their differences, advantages and disadvantages, associated costs, and best practices for implementation.

1. What is Preventive Maintenance?

Definition

Preventive maintenance is a proactive approach that involves performing regular operations on equipment to prevent failures. This includes inspections, adjustments, cleaning, and parts replacements before a failure occurs.

Types of Preventive Maintenance

• Routine Maintenance:This includes daily tasks such as cleaning, lubrication, or basic checks.
• Planned Maintenance:Scheduled interventions at specific intervals (monthly, quarterly, or yearly).
• Conditional Maintenance:Interventions based on the actual condition of the equipment, for example, when anomalies are detected by sensors (vibrations, temperature, etc.).

Importance of Preventive Maintenance

• Reduction of Failures: This approach helps to reduce unexpected failures and service interruptions.
• Improvement of Safety:Well-maintained machines are safer and present fewer risks of accidents.
• Optimization of Productivity:Less downtime means better overall productivity.
• Extension of Asset Lifespan:Regular maintenance maximizes the lifespan of equipment.

Costs of Preventive Maintenance

• Initial Cost:There may be setup costs for periodic inspections and replacements.
• Long-term Cost: Generally, these costs are lower compared to corrective maintenance since failures are avoided, and the lifespan of equipment is extended.

2. What is Corrective Maintenance?

Definition

Corrective maintenance is a reactive approach where repairs are performed after a failure has occurred. It involves restoring the equipment to a functional state after a breakdown.

Types of Corrective Maintenance

• Emergency Maintenance: Immediate repairs following an unexpected failure.
• Planned Maintenance: Interventions scheduled after detecting an impending failure but before it causes a major breakdown.

Importance of Corrective Maintenance

• Failure Management: It is essential for bringing equipment back online after a failure.
• Quick Repairs: Minimizes downtime by responding immediately to a failure.

Costs of Corrective Maintenance

• Unpredictable Costs: Unplanned breakdowns can lead to high costs, including loss of productivity and expensive repairs.
• Labor Costs: Emergency interventions may require overtime or external services, increasing expenses.

3. Comparison Between Preventive and Corrective Maintenance

Criterion	Preventive Maintenance	Corrective Maintenance
Timing	Planned in advance	Reactive, after a failure
Objective	Prevent failures	Repair after a failure
Cost	Less costly in the long run	High costs in case of unexpected failures
Impact on Productivity	Fewer interruptions	Can cause significant downtime
Safety	Improves safety	Increased risks if failures are frequent
Asset Lifespan	Extends asset lifespan	May potentially reduce lifespan if too many repairs are needed

4. Maintenance Tools and Techniques

Computerized Maintenance Management Software (CMMS)

CMMS tools help track, plan, and organize maintenance tasks. They ensure monitoring of interventions and parts to be replaced.

Condition Monitoring

Sensors are used to monitor equipment performance in real-time (vibration analysis, temperature, etc.), allowing for detection of issues before they cause a breakdown.

Asset Management

Tracking and managing equipment to optimize performance and effectively plan maintenance interventions.

5. Maintenance Performance Indicators

• Uptime: Measures the time equipment is operational.
• Total Cost of Ownership (TCO):
• Failure Rate: Frequency of breakdowns over a given period.

6. Advantages and Disadvantages of Both Approaches

Advantages of Preventive Maintenance

• Reduced Downtime: Fewer unexpected failures mean less downtime.
• Lower Costs: Major repairs are avoided, reducing long-term expenses.
• Safety: Improves safety by minimizing failure-related risks.

Disadvantages of Preventive Maintenance

• Initial Costs: Initial investment required to implement a maintenance program.
• Planning Required: Requires a rigorous schedule to maximize effectiveness.

Advantages of Corrective Maintenance

• Flexibility: Intervention is only carried out when necessary.
• Less Planning: No need to schedule interventions in advance.

Disadvantages of Corrective Maintenance

• High Costs: Unplanned repairs can lead to high costs.
• Extended Downtime: Breakdowns can cause significant service interruptions.

7. Impact on the Business

• Productivity: Preventive maintenance optimizes productivity by minimizing interruptions. Corrective maintenance can lead to production losses.
• Short- and Long-term Costs: Preventive maintenance requires an upfront investment but offers long-term savings. Corrective maintenance may seem cheaper in the short term, but unexpected failures increase overall expenses.
• Customer Satisfaction: Well-managed maintenance ensures that services/products are available, improving customer satisfaction and loyalty.

8. Best Practices in Maintenance

• Maintenance Program: Create a schedule for preventive interventions and have a clear procedure for corrective actions.
• Staff Training: Ensure technicians and operators understand the importance of both types of maintenance.
• Data Analysis: Use data from past interventions to adjust and optimize maintenance programs.

9. Case Studies and Examples

Success Stories

Case 1: A company that reduced its maintenance costs by 30% by adopting a proactive preventive maintenance approach.
Case 2: An example where a company suffered significant losses due to relying solely on corrective maintenance, leading to frequent breakdowns.

Common Mistakes

1. Some companies make the mistake of underestimating the importance of preventive maintenance, opting to focus solely on corrective actions when equipment fails. While this may seem like a way to save time and resources in the short term, it often leads to more severe and costly failures down the road. Without regular inspections, cleaning, and part replacements, small issues that could have been easily resolved can escalate into major breakdowns, causing significant downtime and expensive repairs.

2. Lack of Documentation: Another critical mistake is failing to document maintenance interventions. Proper documentation serves as a roadmap for understanding the history of an asset, including past issues, repairs, and preventive measures. Without accurate records, it becomes difficult to plan effectively.

• Track Equipment Performance: Without documentation, companies lose track of when equipment was last serviced or repaired, which can lead to missed maintenance intervals.
• Identify Recurring Issues: Patterns of recurring problems may be overlooked, leading to repeated breakdowns that could have been prevented.
• Plan for Future Maintenance: Effective scheduling of maintenance tasks relies on having a clear picture of what has been done and when. Without records, this becomes guesswork.
• Ensure Compliance: For industries that must adhere to strict safety or regulatory standards, having detailed maintenance logs is essential for audits and compliance checks.

By maintaining thorough documentation, companies can improve maintenance efficiency, reduce downtime, and make better-informed decisions on asset management.

10. Our Maintenance Services

L1 Maintenance After 500,000 Cones Produced

L1 Maintenance is performed after every 500,000 cones produced and involves a series of essential checks and replacements to ensure the optimal performance of the equipment. This maintenance is foundational for the ongoing reliability and efficiency of production operations.

Key Components of L1 Maintenance

During the L1 Maintenance process, the technician will focus on the following tasks:

1. Parts Replacement:

The technician replaces several critical components to prevent breakdowns and ensure smooth operation. The parts typically included in the L1 Maintenance are :



Tasks to be Completed During L2 Maintenance


2. Inspection and Adjustment:

The technician will inspect other crucial machine parts, ensuring that everything is functioning correctly and making minor adjustments as necessary to maintain optimal performance.

3. Report Generation:

At the conclusion of the L1 Maintenance, the technician compiles a comprehensive maintenance report that includes:

• Findings: A summary of the condition of the equipment before and after maintenance.
• Completed Tasks:Documentation of all parts replaced and any adjustments made during the maintenance process.
• Recommendations: Any suggestions for further maintenance or issues that should be monitored closely in future operations.

This maintenance report is essential for tracking the machine's health and guiding future maintenance efforts, ensuring that the production line operates efficiently and effectively.

L2 Maintenance After 1 million cones Produced

Maintenance Level 2 is performed after producing 1 million cones. This maintenance is more comprehensive than Level 1, addressing potential wear and tear that can occur with higher usage. During L2 maintenance, technicians conduct thorough inspections and replace various parts as necessary.

Parts and Tooling List for L2 Maintenance

Tasks to be Completed During L2 Maintenance

Station 1

• Air inlet

  • Inspect air intake to ensure it has a minimum diameter of 1/2 inch.

• HMI

  • Inspect and tighten the HMI arm elbows. Replace them if necessary.

• Carrousel

  • Check the condition of the wheel drive coupling and tighten it if required.

• Push-Rods

  • Inspect and replace the cylinders as necessary.

• Shaker Assembly

  • Check the condition of the oil lite bushings and replace them if needed.
  • Replace the Shaker Rod Bushing.
  • Replace the bushing C-clips.

• Air Filter

  • Inspect the air supply unit for leaks and replace if needed.

Station 2

• Inspect cylinders for condition and leaks. Replace if necessary.
• Inspect the cylinders for condition and leaks. Replace if necessary.
• Check the pivot cam guide for signs of wear. Replace it if needed.
• Inspect hinge bearings for wear and replace them if necessary.
• Check the hinge shoulder screw for wear and replace it if needed.
• Station cleaning and re-alignment.

Station 3

• Inspect the condition of the two bushing guides and replace them if needed.
• Station cleaning and re-alignment.

Station 4

Tumbler Assembly

• Inspect the tumbler front support bearing for wear and damage. Replace it if needed.
• Check gears for signs of wear. Replace if necessary.
• Check the gears for any signs of wear. Replace them if necessary.

Dosing Funnel

• Inspect the vibrator for any damage. Replace it if needed.

Filling Funnel Assembly

• Check the condition of the optical fibers and replace them if necessary.
• Inspect the rubber mounts for wear and tear. Replace them if needed.
• Open and clean the inside of the motion axis.

Needle Actuator

• Check the needle drive block for wear and replace it if necessary.

• Station cleaning and re-alignment.

Station 5

• Inspect alignment coupling for condition and wear. Replace if needed.
• Check the condition and wear of the FLOWER Assembly. Replace if necessary.
• Station cleaning and re-alignment.

Station 6

• Inspect the drive coupling for signs of wear. Replace if needed.
• Check the rotary joint for wear and tear. Replace if necessary.
• Station cleaning and re-alignment.

Station 7

• Inspect the anvil for signs of wear. Replace if needed.
• Check the shoulder screw for wear and tear. Replace it if necessary.
• Station cleaning and re-alignment.

Station 9

• Inspect pivots for the preroll arms for signs of wear. Replace if needed.
• Check the springs of the pivots and replace them if necessary.
• Inspect the alignment coupling for wear and tear. Replace it if needed.
• Check the vertical movement shafts for condition and wear.
• Check the horizontal movement shafts for condition and wear. Replace if necessary.
• Inspect the bellows for any damage. Replace them if needed.
• Inspect vertical and horizontal motion shafts for condition and wear. Replace if necessary.
• Inspect the rod-end for any signs of wear. Replace it if needed.
• Station cleaning and re-alignment.

Conclusion

Effective maintenance of your equipment is crucial to ensuring the performance and reliability of your operations. Through this maintenance guide, we have outlined the necessary procedures for Levels 1 and 2, emphasizing the importance of regular and systematic upkeep. Each workstation plays a vital role in the overall process, and it is imperative that you follow the instructions to ensure all components function optimally.

By adopting these preventive maintenance practices, you can reduce the risk of unexpected breakdowns, extend the lifespan of your equipment, and enhance the quality of your products. Additionally, this contributes to a culture of safety and efficiency within your team, further strengthening your commitment to operational excellence and customer satisfaction.

If you require further information, a quote, or assistance, you can contact us by logging into your portal and sending us a message from there. If you experience difficulty accessing your portal, need information about the portal (tools, etc.), or do not have an account, you can refer to these two documents:
How to Sign Up on the Portal
Introduction to the Client Portal: Purpose and Benefits

We also offer on-site service and can assist you with your maintenance needs remotely if you have an industrial mechanic or electromechanic available on-site. Your dedication and attention to detail are essential for maintaining your high standards. Together, you can continue to deliver superior quality products while preserving the integrity of your systems.