Base maintenance on the machine manual, operating environment, failure history and production consequence. Separate operator checks, planned technical work and condition-based tasks, then stock parts where failure impact and lead time justify inventory.
Why this matters
Dust, washdown, corrosive liquids, heat sealing, high cycling and multi-shift use create different wear and inspection priorities. Routine work must never require guards or safety functions to be bypassed.
Decision table
| Frequency | Typical focus | Evidence |
|---|---|---|
| Each shift | Cleaning, damage, leaks, air pressure, guards, sensors and consumables | Operator checklist |
| Weekly | Belts, chains, guides, tooling, drains and filters | Inspection record |
| Monthly | Lubrication, alignment, pneumatics, electrical condition and calibration | Work order |
| Risk-based | Wear measurement, safety-function proof and backups | Technician report |
| Major service | Life-limited parts, controls, documents and training | Service report |
Information to collect first
- Create an asset register with model, serial and software version.
- List wear parts and failure-critical parts separately.
- Record part consumption and lead time.
- Keep approved PLC/HMI backups and settings.
- Track repeat failures and repair time.
- Review the plan after product or shift changes.
Recommended method
- 1
Start with the manufacturer schedule and site risk.
- 2
Add safe operator-level checks.
- 3
Set measurable replacement criteria.
- 4
Classify spares by impact, probability and lead time.
- 5
Review downtime data quarterly.
Common mistakes to avoid
- Using the wrong lubricant or food-contact grade.
- Replacing parts by calendar alone after the environment changes.
- Holding many cheap parts but no critical controls.
- Allowing unapproved substitutions.
- Resetting recurring faults without root-cause action.
Questions people also ask
What is a critical spare?
A part whose failure can create unacceptable production, safety, quality or lead-time consequences and cannot be replaced quickly.
Should every wear part be stocked?
No. Use consumption, lead time, shelf life, cost and production consequence.
What should be recorded after a breakdown?
The initiating symptom, alarm, product, format, failed part, diagnosis time, repair time and permanent action.
How often should safety functions be tested?
Follow the machine instructions, risk assessment and competent-person inspection regime.
Continue to the appropriate specialist route
Use the links below after defining the product, pack, output and acceptance criteria.