Time is money, and anything that causes a shutdown in a manufacturing facility will cost manufacturers a lot of both. This is why they shouldn’t wait for electrical equipment to malfunction before they start paying attention to it. If they don’t perform regular electrical preventive maintenance on their machines, it’s only a matter of time before something goes wrong. Odds are they won’t be ready for it either. Keeping up with maintenance helps protect systems from regular wear and tear as well as damages caused by environmental conditions or neglect. Read on to learn more about why preventive maintenance of electrical equipment matters so much and how manufacturers can implement it in their facilities.
What is electrical preventive maintenance?
In the simplest possible terms, an electrical preventive maintenance program is a set of tasks technicians perform to keep equipment in prime working condition. Specifically, it involves inspecting, testing and tending to components within the machinery’s electrical systems to prevent failures caused by neglect and wear. Not only does this play an important role in keeping facilities online and ensuring maximum productivity, but it also provides other benefits.
For example, predictive maintenance can prevent arc flashes and other potentially dangerous situations from putting workers’ safety at risk. It also can save money in the long run by extending the lifespan of equipment for as long as possible. In these terms, it’s easy to see why this can be such an important element of manufacturing operations. So, the next question becomes: What goes into an electrical predictive maintenance schedule, and how should it be implemented?
Key components of electrical preventive maintenance
Before implementing any type of preventive maintenance schedule, it’s important to understand what goes into one. The most important elements of any electrical preventive maintenance schedule are:
- Visual inspections: This involves checking the equipment for any visible and obvious signs of wear, damage or overheating. These can include cracks, frayed wiring, burn marks or flickering lights.
- Testing and measurements: For everything technicians can’t see, they need to perform tests such as insulation resistance, thermal imaging and circuit breaker testing to make sure every element of the system is performing as expected.
- Cleaning and tightening: The next step is to go through the equipment and clean all components, making sure there are no loose connections. This is critical for preventing malfunctions.
- Lubrication: Keeping any moving parts properly lubricated helps reduce the amount of friction and wear systems experience. This is a relatively simple job that can add years to the lifespan of equipment.
Electrical predictive maintenance
One of the challenges in maintaining any large-scale manufacturing facility is that different pieces of equipment will require attention at different times. Depending on the nature of the components and how heavily they are used, similar parts may not all wear out at the same rate. Because it’s critical to keep everything in good condition, this is why manufacturers must integrate electrical predictive maintenance into their overall program.
The idea behind predictive maintenance is scheduling work when it is most likely to be needed. For example, equipment lubrication for parts that don’t see as much use as others takes time away from more-pressing tasks. If technicians can predict when that part needs lubrication based on how frequently it has been used, however, they stand a much better chance of keeping it in service and allocating resources in the most efficient manner.
Predictive maintenance relies on data to be effective. Technicians and operators need to know how often systems see use, how heavy their load is and what condition they’re in at the present time. Fortunately, advancements in sensor technology and diagnostic software have made this much easier.
Condition monitoring sensors connected to the Industrial Internet of Things (IIoT) provide constant updates regarding environmental conditions and system performance through vibration analysis, thermographic testing and more. When this information is fed into software, technicians can predict when certain elements of their systems will be most likely to fail. This gives them the ability to schedule work when it will be most appropriate, ensuring the most efficient allocation of time and resources. Combined with a preventive maintenance schedule, this means manufacturers can provide comprehensive care to their most valuable assets and keep them online for as long as possible.
Electrical preventive maintenance checklist
Here is a sample checklist to help technicians and operators start planning their preventive maintenance program:
Visual inspections
- Check for signs of wear, damage or overheating on all electrical components
Testing and measurements
- Perform insulation resistance tests
- Conduct thermal imaging to identify hot spots
- Test circuit breakers for proper functioning
Cleaning and tightening
- Clean all electrical panels, enclosures and components
- Tighten all electrical connections to prevent loose connections
Lubrication
- Lubricate moving parts in motors and electrical equipment
Documentation
- Record all findings and maintenance activities
- Note any issues and schedule follow-up actions if necessary
Safety checks
- Ensure all safety devices and interlocks are functioning correctly
- Verify proper labeling of all electrical panels and switches
Backup systems
- Test backup generators and UPS systems for reliability
- Check battery health and replace if necessary
Benefits of electrical preventive maintenance
Implementing a preventive maintenance program for electrical equipment provides manufacturers with numerous benefits, including:
- Increased safety: Keeping equipment in good working order prevents electrical fires and accidents that can lead to injuries.
- Reduced downtime: Regular upkeep helps ensure equipment remains online for as long as possible to prevent production stoppages and unexpected failures.
- Cost savings: By addressing potential issues as early as possible, manufacturers can keep their repair costs in check.
- Extended equipment lifespan: With regular care and preventive maintenance, electrical systems and components last longer on average.
Preventive maintenance makes a difference
Manufacturers who don’t implement a preventive maintenance plan are gambling with their assets and their productivity. The electrical components of systems are some of the most sensitive and important aspects of the modern manufacturing setup, so it stands to reason that they must be cared for properly to get the most out of them. The experts at ATS have all the knowledge and expertise to help manufacturing companies set up and manage a maintenance schedule that makes the most sense for their needs. Get in touch with us today to learn more about our preventive and predictive maintenance services.
