Relax! 5 tips for less downtime of your installation
"Why aren't our machines working?" An essential question for a production company that wants to produce 24/7. Too much or too long downtime can make the difference between profit and loss.
The influence of control technology on continuity
Control technology is also playing an increasingly important role in production companies. The application of PLC technology , control screens, servo motors and robot arms has significantly increased the efficiency of your production. But this also makes you vulnerable and a reliable control system is becoming increasingly important. It does need sufficient maintenance. An empty backup battery or a PLC that can no longer be supplied can have major consequences.
Action
The technology is becoming increasingly complex, TD personnel are hard to find and trusting that the machine builder will still be there after 5-10 years is a risky option. What can you do yourself?
Step 1 Map the systems
Mapping makes you aware of which systems are used in your machines. In any case, start with the essential components such as: control (PLC/PCB/computer), visualization (HMI/SCADA), drive (servo/robots). Furthermore, each machine has its own unique products that are essential for the operation of the machine, but for which replacement components are not easily found. Note down the brand and article number of everything and take good and clear photos.
Step 2 Backup software
We are regularly called that a machine, ship or building-related system no longer works because the control has broken down and there is no backup of the software . Sometimes we are successful and there is still a printed version of the ladder diagram. But often we have to develop new software via reverse engineering with information from the customer. This means a standstill of several days to sometimes months. So make sure you have backups of all software, preferably directly from the supplier. If this does not work, we also regularly make backups of systems that have been running for 20 years.
Step 3 Replace battery in time
Some products are equipped with a battery that retains the memory when there is no power to the machine. This must be replaced regularly. Now that the hardware has been mapped, you can include the battery in your preventive maintenance plan. If you find out afterwards, it often means that the machine is started up and the PLC no longer contains any control software. Then you can only hope that there is a backup of the software. If not, the consequences are clear. A 15-minute job for €30 can ensure that your production can continue to run.
Step 4 Get spare parts
Now that the system has been mapped, you can also see for most products whether they are still available and what the MTBF (Mean Time Between Failures) value is. If they are no longer available, you can already look for an alternative and what that means for you. Is the hardware still available? Then it becomes a simple calculation: do you keep the component in stock, pre-programmed or not, or do you ensure good agreements with a supplier.
Step 5 Find a partner who can support you
There are enough companies that have the technical knowledge and programming software to take care of all this themselves. But if you do not have the knowledge or the programming software, because ultimately you are a production company and not an engineering firm , then you can seek cooperation with a partner who specializes in this. They can help you with mapping, preventive maintenance, making backups and often also with keeping the hardware in stock and with 24/7 support if desired!
Make a checklist!
Despite the complex technology, suppliers of PLC, HMI and motors have very reliable products that sometimes last 25 years without problems. Because of this, you often assume that everything will continue to 'run'. Do you want to prevent downtime and costs? Then walk through your machine park or talk to a hardware supplier or engineering firm.
