Predictive Maintenance versus Repair Maintenance

By Frank J. Tulipano, Sales Consultant, Customer Support and Services
Uhlmann Packaging Systems LP (Towaco, NJ)

Frank J. Tulipano

Most automobile owners follow a preventive maintenance schedule with their cars based on the manufacturer’s recommendations. The majority of car owners would prefer to spend a small amount on regular car care and maintenance rather than risk something wearing out or breaking, resulting in an expensive repair bill.

But how consistently are the maintenance and servicing recommendations followed for packaging machines? Packaging machine maintenance is required to ensure maximum machine efficiency and reliability in the long term. The required maintenance for packaging machines depends not just on the operating hours, but on a lot of other factors, too. Some lines run only 8 hours per shift, while some operate over two or three shifts, and yet others are only in operation for a few hours per week. Some machines package just one product, while others are required to package many different products per day. The maintenance program for each machine depends on the processes it performs.

Key Questions
The following questions should be asked as part of a routine maintenance program:
• Will your maintenance personnel be able to identify all the services that are required?
• Are your packaging machines serviced by your own mechanics or a specially trained customer and support services technician after approximately 2000 hours of single shift operation?
• In lieu of machine run time, is your maintenance based on calendar time?
• Is your maintenance carried out on a proactive basis or a reactive “repair” basis?
• And what happens when your machine breaks down?

Maintenance Based on Machine Operating Time
The NetCare maintenance planner from Uhlmann Packaging has been developed to help packaging machine owners stay on top of their maintenance schedule. A highly functional and visible tool, NetCare points out upcoming service dates and prompts the staff to conduct certain maintenance measures. Services and schedules are decided in accordance with individual utilization data.

The NetCare system establishes the “physical condition” of the machine from the signals it receives. These data are then compared with preconfigured parameters in accordance with the maintenance instructions for that type of machine. It details which maintenance jobs are required after a certain number of operating hours as well as whether they can be carried out by a mechanic or a certified customer support and services technician.

Such details are taken into account during a meeting with the customer prior to configuring the NetCare system. The customer can also define the maintenance schedules based on the number of operating hours or in accordance with customized standard operating procedures (SOP) or other demands made on the machines.

Automatically Tracking More than 120 Points
The focus of NetCare is to schedule maintenance based on the machine operating time, based on turning of the main drive motor. Uhlmann assigns operating times to parts such as chains, bearings, or belts based on its machine maintenance documentation or experience. Included with the NetCare upgrade is a “mini PLC.” Therefore, the validation process of the equipment and the safety of the operation of the machine are not affected. NetCare keeps track of approximately 120 points. Therefore, required maintenance is identified by a group of components, since a machine contains more than 120 parts. NetCare can indicate when bearings need greasing but only based on strokes or timed intervals.

For example, in a thermoformer, the punch tool contains ball cage bearings, which the punch tool rides up and down on. In this case, operators would keep track of the number of strokes of the punch tool. But for a bearing that is located on a rotating shaft, operators would keep track of its operating time. For cartoners, NetCare would include the rotary booklet feeder and rotary carton pick up mechanism. NetCare’s standard package provides all required maintenance for defined items and components based on machine configuration, when the machine was originally delivered, and any upgrades that are contained in our files. The system allows customers to modify maintenance items or define new items, such as add their own PM documents.

Uhlmann’s NetCare does not replace the need for a maintenance agreement. But it does take the guess work out of when maintenance is required based on the operating time of the machine.

Since 2002, Frank J. Tulipano has been a customer support and services sales consultant with Uhlmann Packaging Systems LP. His responsibilities include the sales of rebuilt equipment, equipment upgrades, tooling, and accessories, including customer service. Frank has a Master’s and Bachelor’s degree in Mechanical Engineering and an EIT license.

This article was adapted from “Predictive Maintenance versus Repair Maintenance to Ensure Optimal Packaging Machine Performance,” first published in the October 2009 issue of Unit Dose Alert.