July/August 1988
Considering the substantial investment you’ve made in your cranes, shear, baler, and other equipment, practicing preventive maintenance is a small price to pay for keeping the machinery in motion. The expert advice and checklists that follow will help you fine-tune your PM program and reduce equipment downtime.
By Murray Brant, Doris Kijek, Jeff Miller, and Ken Obarski
Murray Brant is lead man, crane operator with Miller Compressing Company, Milwaukee, Wisconsin. Doris Kijek is a secretary and administrative assistant at the firm. Jeff Miller is vice-president; and Ken Obarski is lead man, maintenance man, and electrician.
With the high replacement cost of scrap processing equipment, it is imperative that companies implement a strong preventive maintenance program. Such a program requires a shared philosophy, commitment, and team effort among managers, equipment operators, and maintenance people. Employees must be encouraged to inspect, probe, and look continuously for ways to detect trouble and improve performance of equipment. With everyone on the lookout for problems, minor adjustments can preempt major repairs.
Specific steps must be performed for each piece of equipment. Following are general guidelines for a successful PM program, plus suggested checklists for daily and monthly completion.
Training
Training is an important element of an effective preventive maintenance program. Equipment manufacturers' manuals are a good place to start. Operators who are trained to run their equipment correctly not only are more productive, but are less likely to unknowingly abuse their machinery. A machine that is not operated properly needs more than routine maintenance to keep it running. Parts will need replacement prematurely, unplanned downtime will occur, and production deadlines will be missed.
A well-trained operator and maintenance person working together to keep the equipment running are valuable assets. Train your operators to inform managers when an equipment problem arises, regardless of its severity
Tools
Today's machinery is sophisticated and often requires specialized tools. Without proper tools, maintenance--planned or unplanned--cannot be performed efficiently. Makeshift or broken tools are dangerous and should be replaced.
Housekeeping
Good housekeeping in a preventive maintenance program is essential. Keep your equipment clean--grease and oil can hide trouble spots. Make sure your tools are inventoried and organized. A clean maintenance shop and clean machinery decks are also important. Avoid injuries by keeping the floor free of clutter and surfaces free of grease.
Re-Engineering Equipment
Look for ways to make your equipment more efficient and increase the life of its parts. Equipment limitations and weak points are apparent after a period of time. Work with equipment manufacturers on improving your machinery.
Using Service Checklists
'Daily service checklists are required for every piece of equipment in operation. Current records of inspections, repairs, and overhauls must be available to operators, maintenance people, and managers. History records are required since it is impossible to remember all the work that's been done to a particular piece of equipment.
A daily inspection, greasing, and fluid level check serve two purposes. First, if a major problem is discovered, the equipment can be repaired before being put back into operation. Second, by using daily checklists, the operator and maintenance man can develop schedules for their weekly or biweekly maintenance work.
The importance of these checklists means operators and maintenance men must not be permitted to make haphazard check marks on a list just to "get it over with."
Overhauls
Periodically, each piece of equipment requires a major overhaul. It usually is more feasible to overhaul scrap processing equipment than to replace it. Plan overhauls in advance to ensure that time is allotted, replacement parts are on hand, and a work plan has been written so the job can be completed efficiently.
Encouraging Teamwork
The way a scrap facility is operated determines how well preventive maintenance is performed. Operators should feel that they are an important part of the team. By listening to them and working with them, you can make that happen.
If a piece of equipment runs for more than one shift, make sure operators exchange information either verbally or in writing. If an operator on one shift alerts the operator on the next that there may be a problem, the operator coming on shift may be able to prevent serious damage to the machinery.
A well-structured and -documented preventive maintenance program helps you gather the information you need to plan maintenance work and reduce equipment downtime. Of course, even with a well-planned maintenance program, not all breakdowns will be eliminated. It will take the combined efforts of your entire team to increase equipment reliability, keep your facility productive, and enable you to process scrap at the lowest possible cost.
[SIDEBAR]
Maintenance Tips
Before using your shear every day, check the gibb bolts of the shear head to make sure they are tight.
An essential shear maintenance practice: Check the pump room several times a day for oil leaks.
Every day, before using your baler, check the oil level of the pistons pump to ensure pistons are lubricated.
A daily crawler crane maintenance step: Grease the cargo block to lubricate the bearing.
Considering the substantial investment you've made in your cranes, shear, baler, and other equipment, practicing preventive maintenance is a small price to pay for keeping the machinery in motion. The expert advice and checklists that follow will help you fine-tune your PM program and reduce equipment downtime.