Small issues can become costly – why preventive machine maintenance pays off
A machine breakdown rarely happens without warning. In many cases, the first signs have appeared earlier: an unusual noise, uneven movement or a cutting result that gradually starts to deteriorate. By identifying these signals early, it is often possible to avoid both emergency repairs and costly production downtime.
In a sheet metal workshop, machines are part of an interconnected production flow. When a folding machine, double folder, cut-to-length line or roll forming machine stops, several production steps can be affected at the same time. Material begins to pile up, deliveries are delayed and operators are forced to find temporary workarounds.
Preventive maintenance is about identifying wear, incorrect settings and minor deviations before they begin to affect quality and production capacity.
A US study from NIST found that manufacturing companies making greater use of preventive and predictive maintenance experienced significantly less unplanned downtime and fewer quality defects than companies that primarily relied on repairs after breakdowns.
Operators often notice the first signs
The person working with a machine every day knows its normal sounds, movements and operating rhythm. That is why the operator is often the first to notice when something changes.
On a folding machine, this may become apparent when angles are no longer consistent along the entire profile or when the operator needs to make more corrections than before. On a cut-to-length line, worn blades or incorrect pressure settings on the straightening rollers can lead to burrs, deformation or poorer cut quality.
Vibrations, leaks, longer cycle times and recurring error messages should also be taken seriously. A machine may still be running, but at the same time it may be costing money through additional rework, increased material waste and inconsistent quality.
A simple routine can identify problems early
Preventive maintenance does not have to begin with a complex system. A clear routine covering what operators should check before and after production can make a significant difference.
Checks may include:
- Cleaning the machine and surrounding work area
- Inspecting tools, blades and wear parts
- Checking lubrication and fluid levels
- Inspecting hoses, cables and connections
- Checking guards, sensors and safety functions
- Recording error codes and recurring quality issues
Maintenance requirements vary depending on the type of machine, operating hours, material and working environment. The machine manufacturer’s instructions and recommended service intervals should always be the starting point.
Documentation makes troubleshooting easier
When a problem occurs, the service technician needs to know when it starts, how often it happens and under which operating conditions it appears.
A simple maintenance log containing notes about changes in accuracy, unusual noises, error codes and previous actions provides valuable information for troubleshooting. It can also reveal patterns and help the company replace a worn component before it causes a breakdown.
The right spare parts reduce downtime
Consumable parts and components subject to known wear should be identified in advance. A company does not need to keep every component in stock, but it should know which parts are most critical and how quickly replacements can be delivered.
For machines that are central to the entire production flow, keeping a selection of critical spare parts on site can significantly shorten downtime. At the same time, the parts must be designed for the specific machine, as incorrect components can affect accuracy, performance and safety.
Planned service gives you greater control
The key difference between planned service and emergency repair is often who decides when the machine will be standing still.
Planned maintenance can be scheduled between major jobs or coordinated with other planned production stops. A breakdown, on the other hand, often occurs when production is at its busiest and delivery deadlines are under pressure.
During professional servicing, the machine’s mechanical, hydraulic, electrical and digital functions can be checked. Wear parts can be replaced and settings adjusted before deviations begin to affect finished components.
Service close to your production
When a machine is critical to daily production, access to technicians who know the equipment and can quickly identify the cause of a problem is essential.
CIDAN Machinery Group has a global service organization providing preventive maintenance, troubleshooting, repairs, spare parts, installation and operator training.
The goal is not simply to get the machine running again after a breakdown. It´s also about reducing the risk of the problem recurring and helping customers maintain the machine’s accuracy and production capacity over time.
Learn more about CIDAN service and how planned maintenance can help reduce the risk of unwanted production downtime.
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