We all know electronics don't last forever. However, preventive maintenance does help extend the life of your electronic modules. It reduces the risk of malfunctions, reduces any downtime and increases the efficiency of machines and production lines.
How? UNIS Group lists five tips.
Tip #1: Inventory of electronics
Which electronics are actually installed? And just how essential are these modules for production? Insight prevents surprises. It offers certainty to make an inventory of the electronics that are installed.
UNIS Group is happy to offer you this certainty with the inventory and evaluation service. An extensive inventory of the installed electronics is carried out on site. We clarify this in a detailed report with an indication of which electronics may pose a risk.
We evaluate the future demand for parts, their availability, which spare parts you have in stock, and for which electronics we can provide service. Thus, we provide you with the basis to make the right decisions for future production performance.
Tip #2: Identify risks through analysis
The most effective way to clarify where the risks in the machinery are located is by doing a risk analysis. A risk analysis is the follow-up to the inventory.
Outdated electronics are one of the biggest risks for downtime. Machinery ranging from 10, 15 to 20 years old can be found in many production companies. With older production lines, parts are not always available, or only available abroad, and with a long delivery time. An overview of these risks provides insight into the consequences and duration of downtime due to a malfunction or broken parts. For example, being aware of critical parts allows you to efficiently supply your warehouse with spare parts.
In short: the knowledge that a risk analysis provides is valuable in reducing a few weeks or even months of downtime to a few hours. When you outsource the risk analysis to UNIS Group, we submit our recommendations afterwards. This can vary from purchasing those hard-to-find spare parts, to a complete renewal of the system.
Tip #3: Gain insight with a maintenance plan
Insight into the systems prevents surprises, reduces risks and provides guidance in drawing up a maintenance plan and schedule. With a maintenance plan, it is clear when which (time-sensitive) parts need to be replaced preventively. It is also easier to make informed choices about future repairs, overhauls, purchasing and migration of installed electronics.
A maintenance plan can be extended with the drawings of the equipment, the history of the maintenance per part and procedures. By keeping these documents up to date, you reduce the duration of downtime in the event that the machinery comes to an unexpected standstill.
Thanks to the documentation, the engineers can immediately get started with the right information to solve the problem as quickly as possible.
Tip #4: Take on simple maintenance jobs yourself
Industrial environments involve dust, greasiness, and in many cases, heat too. These three elements negatively affect the optimal functioning of electronic modules. That’s why it is important to proactively perform certain actions yourself on a regular basis.
What should you consider?
- Keeping the working environment clean. Less filth in the environment means less chance of filth in the machine or production line.
- Filters must be replaced. These become clogged with grease and dust, so they cannot filter or let the air through properly.
- Check relays. Is there signs of oxidation? Then it is necessary to replace it well in advance, before the relays fail unexpectedly.
- Clean fans and grilles. When these become dirty or clogged, the module or device is not properly cooled.
- Replace batteries in time. Many backup systems run on batteries. With flat batteries, the system cannot do its job properly and you are left empty-handed during unexpected downtime.
Making regular software backups is a sensible way to shorten the length of possible downtime. When a machine's software is erased due to a breakdown, downtime or a repair, a backup can be restored.
Obviously, this is the fastest way to get back into production. When a developer has to rewrite the software for lack of a backup, downtime can take weeks.
Tip #5: Create predictability
A warning that a malfunction is imminent: now that would be perfect. Unfortunately, it doesn't work that way. However, there are indicators that could mean an imminent production stoppage, such as occasional outages, errors in network communication, temperature changes or peaks/dips in voltages.
UNIS Group has an extensive service, including on-site service. Our engineers are equipped with tools for analyzing PROFINET and PROFIBUS networks. This detects and exposes the problems in these networks. These networks must be in good condition for successful business operations.
A PROFIBUS or PROFINET network is complex and can connect thousands of devices. The consequences of an error in communication are immense. The information from the UNIS Group analysis reflects the quality of the network. You will discover the weak links, and the diagnostic report offers insight as to how the problem can be solved.
Preventive maintenance reduces downtime
Preventive maintenance plays a major role in extending the life of your electronic modules and preventing downtime. With the above tips for preventive action, you reduce the likelihood of (extended) downtime.
Do you have any questions about this blog, or would you like to know with which service we can best serve you? Feel free to contact us. We look forward to helping you! You can reach UNIS Group via int@unisgroup.com or +31 566 72 61 91.
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