Page 18 - MetalForming September 2012

Plan Press Maintenance
safety systems, automation equip- ment, drives, cushions, controls, etc. This practice will make a system rela- tively future-proof and increase response time when service or repair is needed. Also, we reduce pressline downtime and avoid costly part-pro- duction delays.
Critical Situations
The service life of several common components (mechanical and electri- cal) recently has plagued the uptime of several press shops. Such components should be assessed for future obsoles- cence (see the table, Suggested Com- ponents to Assess for Planned Obso- lescence).
For example, delivery time of a par- ticular pump used in one press shop recently increased from six weeks to as long as 12 months. Yet another stam- per found that when a motor was no longer being manufactured, it faced a lead time of more than 16 weeks to get its press back up and running, account-
ing for engineering time, the time need- ed to update specifications, and addi- tional onsite assistance. And in yet another instance, a stamper found that a minor component used in a press electrical system no longer was being manufactured. This led to reengineer- ing of a used component to employ as a retrofit—a solution that took 12 weeks to develop and implement.
Bear in mind that timely supply of replacement parts is not completely under the control of the component suppliers. The extended time to obtain a replacement part can be due to tech- nology changes, high demand or new part designs. Critical components to evaluate include PLC controls, motors/ drives, electrical components, pumps, valves and seals.
Develop and Execute a Plan with Support
It is important for NAFTA-region press shops to act now. The first step to avoiding unplanned downtime is to
start with an equipment assessment by a press expert for the entire opera- tion. From this assessment, create a maintenance plan that identifies com- mon problem areas and anticipates the need for part or subsystem replace- ment. By using this strategy, companies can plan downtime to repair parts that may become at risk during high-output periods. In fact, this enables service providers to preorder parts with long lead times, and schedule time for press rebuilds or overhauls for outdated components.
Proper planning prevents expen- sive panic, so plan for the future by conducting routine PM inspections to assess your vulnerability to obsolete press-system parts. This is not a new concept; the approach has worked in the past and has reduced the amount of lost uptime. Equipment assessment is a part of continuous improvement, allowing a company to define critical areas and develop an action plan to reduce risk. MF
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MetalForming/September 2012
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