Page 16 - MetalForming September 2012

Plan Press Maintenance
Follow the advice offered here, including planning for component obsolescence, to avoid unplanned press downtime and expensive emergency repairs in the pressroom.
As the U.S. manufacturing sector rebounds from the recession, metalformers face several obsta- cles to maintaining efficient and cost- effective press-shop maintenance and repair schedules. These obstacles can create a critical pinch
point that can lead to extended, unplanned downtime—and expensive repair costs. Learning from recent critical situations at other facilities, and understanding the root causes, can help stamping operations create a plan to min- imize their own risks.
These obstacles are local as well as global in nature. Locally, press pro- duction requirements have increased while many press components have become obsolete. And, these presses often are allowed limited downtime for maintenance. In addition, most press shops are supported by a reduced post-recession stock of spare parts, with fewer skilled people available to work on the equipment.
Esther Holewa is customer service sales representative, Schuler Inc., Canton, MI: 734/207-7200; www.schulergroup.com.
BY ESTHER HOLEWA
Globally, we see increased demand for press-system controls and components required for maintenance and repair. This increased demand has created in some cases extremely long lead times to obtain replacement components, as
long as several months. Such delays make it virtually impossible to respond quickly to emergency situations.
In the event of a catastrophic failure of a key press component, the com- ponent may need to be reengineered
Suggested Components to Assess for Planned Obsolescence
Controls
(inactive/ discountinued)
Motors/ Drives
Electrical
Pumps
Valves
Seals
• Allen Bradley PLC5
• Siemens S5
• Moog
• Qnx
• MS-DOS
• Servo drives
• Amplifier
cards for hydraulic applications
• Murr
• Semikron • Phoenix
contacts
• Hydraulic pumps
• Rexroth
• HS3 and IMO
• Vane and gears
• Hydraulic
motors
• Servo valves • Proportional
valves
• Slide
• Cushion • Cylinders
Press Life-Cycle Curves—Impact of Planned Maintenance
1600 1400 1200 1000
800 600 400 200
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 Time (years)
Active Maintenance Expected on partial overhauling Reactive Maintenance Expected on complete overhauling
14 MetalForming/September 2012
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Lost Production (hours)