Equipment Maintenance

Proper maintenance ensures safety, efficiency, and equipment longevity.

Preventive Maintenance Schedule

Daily Checks:

Visual inspection for damage
Check fluid levels (oil, coolant, hydraulic)
Verify safety guards in place
Test emergency stops
Clean work area
Log in daily checklist

Weekly Maintenance:

Lubricate moving parts
Check belt tension
Inspect hoses and fittings
Clean filters
Calibrate sensors
Record in maintenance log

Monthly Service:

Deep cleaning
Replace filters
Check electrical connections
Inspect wear parts
Verify calibration
Professional inspection if required

Using the CMMS

Computerized Maintenance Management System:

Log in to CMMS portal
View assigned work orders
Complete tasks per procedure
Record parts used
Document labor hours
Close work order when complete
Note any issues discovered

Reporting Equipment Issues

Minor Issues:

Submit work order in CMMS
Include equipment ID number
Describe problem clearly
Note when issue started
Indicate urgency level

Safety Concerns:

Stop equipment immediately
Tag out equipment (LOTO)
Notify supervisor right away
Submit emergency work order
Do not attempt repairs yourself

Lockout/Tagout (LOTO)

Required before maintenance:

Prepare: Identify energy sources
Notify: Inform affected employees
Shutdown: Use normal stopping procedure
Isolate: Disconnect all energy sources
Lockout: Apply locks to isolation devices
Verify: Test that equipment won't start
Perform Work: Complete maintenance safely
Remove Locks: Only the person who applied them
Notify: Alert employees before restart

Authorized Personnel

Who can perform maintenance:

Operators: Daily checks, basic cleaning
Maintenance Techs: Scheduled PM, repairs
Electricians: Electrical work only
Engineers: Calibration, programming
Contractors: With escort and permit

Spare Parts Management

Obtaining parts:

Check CMMS for part numbers
Search parts crib inventory
Submit parts request if not in stock
Use proper parts only (no substitutions)
Return unused parts
Report obsolete parts

Documentation Requirements

Always document:

Date and time of service
Work performed
Parts replaced
Measurements taken
Issues found
Technician name/badge
Equipment run time/hours

Equipment History

Tracking maintenance:

Complete history in CMMS
Review before major work
Identify recurring issues
Plan for replacements
Calculate total cost of ownership

Predictive Maintenance

Advanced monitoring:

Vibration analysis
Thermal imaging
Oil analysis
Ultrasonic testing
Motor current signature analysis
Scheduled by maintenance planning

Emergency Repairs

When equipment fails:

Ensure area is safe
Implement LOTO procedures
Assess damage
Determine parts needed
Obtain supervisor approval
Expedite parts if critical
Perform repair
Test thoroughly before production
Document root cause

Cleaning Standards

Equipment cleanliness:

Daily: Remove debris, wipe surfaces
Weekly: Deep clean accessible areas
Monthly: Clean internal components
As Needed: After spills or contamination
Use approved cleaners only
Ensure equipment is off and locked out

Calibration

Ensuring accuracy:

Scheduled per equipment requirements
Performed by qualified personnel
Documented with calibration stickers
Out-of-tolerance equipment tagged
Records maintained in CMMS

Training Requirements

Maintenance personnel must complete:

Equipment-specific training
LOTO certification
Safety training (annual)
CMMS system training
Manufacturer training for complex equipment

Equipment Maintenance Procedures