Taking Action with Preventative Maintenance in Forges

March 25, 2014 / , , , ,

In most cases, one of leading causes of lost productivity is breakdowns. Equipment and tooling failures create bottlenecks that throw off delivery schedules, reduce efficiency, and increase costs. And in today’s competitive market, forges just can’t afford downtime.

While some breakdowns are inevitable, more and more companies are realizing that proper maintenance and proactive care of equipment and tooling can, in fact, reduce their occurrence. When equipment is well maintained, it is more reliable, more predictable, and more productive.

Really, the case for preventative maintenance (PM) program isn’t a hard one to argue, especially when so many manufacturers are seeing the positive impact it can have on the bottom-line. For example, according a recent benchmark study from the LENOX Institute of Technology, 70% of industrial metal-cutting organizations that report their scrap and rework costs are less than 5% also say they “always” break in their band saw blades. This provides strong economic validation for the proactive care of equipment such as saws and blades. By breaking in blades properly, organizations are able to reduce “soft” failure that leads to waste and scrap and that eats into their bottom line. It also keeps operators productive and reduces unnecessary tooling costs.

While the theoretical benefits of a PM program are clear, like any continuous improvement initiative, it requires some strategy to be successful in practice. The following are just a few best practices for managers to consider when implementing a formal PM program: