Q: Why do I need a preventive maintenance program?
A preventive maintenance program plays a significant role in assisting your maintenance personnel with minimizing unexpected machine downtime. This allows your production planner to make informed decisions associated with production schedules as a result of pre-planned maintenance outages.
Our program includes a thorough inspection of the selected machine tool with the goal of providing a longer life cycle. Obviously, these results cannot be achieved with an occasional ‘one time’ maintenance check-up. Although preventive maintenance programs cannot take the place of necessary machine maintenance, they can go a long way towards minimizing unexpected repairs and downtime.
Q: How does Konecranes Machine Tool Service tailor their preventive maintenance program to meet my needs?
We go to great lengths to insure that our customer’s fully understand the value they receive when contracting our services. After the initial service has been performed, we review the results with your team. During this review, it will be determined as to what changes or modifications, if any, are necessary to promote and prolong machine efficiency.
In order to benefit from the program, it is essential that all pertinent data for each machine be documented and stored. Capturing this data allows us to make informed decisions regarding your equipment’s projected maintenance needs. It is vital to identify benchmarks for all perishable components in order to identify specific weaknesses associated with a component or unit. To achieve this, we have developed forms specific to each area and function of our customer’s machine. With input/assistance from our customer, we select the appropriate form(s) and work scope to be used with each machine. Utilizing our vast technical experience along with published machine manuals, we consolidate all pertinent information into one report. This report is provided to our customer for future reference. For unconventional machines, we will develop a program supported by the appropriate documentation that matches the machine’s requirements.
Q: Is it too late to start a preventive maintenance program on an older machine?
The initial return on your program is of little value when implemented on a machine that is already in poor condition; however, incremental corrections of known problems will eventually restore the machine to optimum operating conditions.
To assist our customers in returning their equipment to optimum condition, we provide a “recommendation” section in our documentation. This section identifies items that require immediate attention.
If we discover a situation that would compromise the integrity of the machine, it is brought to the immediate attention of our customer. Normally, our customer’s maintenance personnel can address the items listed in the recommendation section.
Q: How often should a machine be calibrated?
The answer, of course, depends on a customer’s specific situation. Frequency of calibration depends on machine usage, including hours of operation and the type of work the machine is performing. For example, if a lot of work is done in aluminum, this doesn’t produce nearly the machining stresses that machining molds or dies from tool steel would. So a machine cutting aluminum would probably require calibration less often.
Typically, companies should consider calibrating their critical machines every six months, depending on the tolerances of their work. However, if a machine is crashed or if it begins to produce parts that are out of tolerance, it should be re-calibrated immediately to eliminate or reduce any damage that may been done to the machine.
Q: What sort of report is provided during a Ballbar Analysis?
A visual report is provided showing the machine’s positioning and geometrical errors captured during the test. These errors appear as small deviations in the radius of the ballbar movement. The results are then plotted on the screen to reveal how accurate the machine performed during the interpolation test.
If the machine performs accurately and has no significant errors, the plotted data would show a circle that is within tolerance. The presence of any errors will distort this circle as reflected in our sample document. Software automatically analyzes the data and diagnoses specific machine error characteristics. Each error is ranked according to its significance to overall machine accuracy. Maintenance can then be performed to correct these errors.
Q: Are my records saved at Konecranes MTS?
Yes. In addition to providing our customers with a written report, Konecranes Machine Tool Service retains a copy of your test results in our service records.