All machine systems will require attention and repair, regardless of the rigorous maintenance schedules established. Machine tool repairs extend the life of any equipment, keeping them in good working order for longer periods.
Initial, the manufacturer usually bares some of the machinery repair costs through the warranty service. However, once the warranty period elapses, the burden shifts to the end-user, which may significantly increase maintenance costs.
Repair. Rebuild. Replace
Maintenance supervisors have to think through delicate choices on whether to repair, rebuild, or replace a hydraulic system. Various factors may influence the decision, including the final costs of each of the actions.
Repairs involve refurbishing the machine parts to attain close to the original properties, including shape, dimensions, tolerance, and clearance limits. The rebuilding process takes apart the machine block, reengineering it to an almost-new status, albeit at a lower cost. Replacement means having to take out the old equipment, decommission it and install a new machine in its place.
The 50/50 rule of equipment maintenance is popular among most companies. Replacing the equipment only occurs when the total expense of machine repair exceeds more than half the cost of purchasing a new one. Repair costs tend to rise gradually over time to about 30%, at which they increase sharply to over 50% the following year. Plant managers need to keep track of the fees and lower their machine shop repair costs. Here are some ways to achieve it.
1. Track and Monitor Repair Expenses
It is essential to track maintenance costs for a specific piece of equipment. Accurate and detailed records can help determine the money spent on labor, parts, and supplies for the machine repair since its purchase.
Proper record-keeping also aides in making data driver decisions on maintenance schedules and repairs. A computerized maintenance management system can track costs, create a preventive maintenance schedule, and update your inventory. Create an accounting system that generates information on how much you spend on machine shop repairs.
2. Establish Good Preventative Practices
Regular machine breakdowns and malfunctions can be easily avoided through an excellent preventative maintenance strategy. Regular checkups on your machine parts can identify issues much earlier and create a corrective action plan.
The preventive maintenance services ought to be done by expert technicians from an experienced machine shop. The schedule should also align with the manufacturer’s specifications that may mandate a check after a specific number of active running hours.
3. Regular Operator Training
Reactive maintenance strategies end up rising the machine shop repair costs as the damage has already been done. Regular training of your technicians can help them identify malfunctions faster and report the issues on time. The predictive approach may help keep the machines running for longer, reduce your downtime, and lower your maintenance costs.
4. Choose the Right Machine Shop Services
Excellent machine shops build genuine and long-term partnerships through quality repair services that reduce incidences of breakdowns of the machines. Quality workmanship, coupled with high precision machine components, can keep the equipment running for longer without the need for replacements. Plant managers may also enjoy warranty covers for the repairs done, thus keeping the machine shop repair costs low.
Maintenance supervisors may have a hard time balancing between repairs, rebuilds, and replacement of their machines. Machine shop repair services can help extend the life of their equipment. Again, keeping repair costs also helps boost your bottom-line.
