← BackMachines and Maintenance
Purpose: keep critical machines operational using preventive schedules, diagnostics, and disciplined spares strategy.
Quick Start
- Create asset list with criticality ranking.
- Set maintenance intervals by runtime or calendar.
- Standardize inspection points and measurement baselines.
- Stock top failure spares before breakdowns occur.
Maintenance Layers
| Layer | Frequency | Tasks | Outcome |
|---|
| Operator check | daily | visual leaks, sound, temp, vibration | early anomaly detection |
| Routine service | weekly/monthly | lubrication, tension, filter checks | wear control |
| Planned overhaul | quarterly/annual | component replacement and alignment | failure prevention |
Decision Table
| If this happens | Do this now | Backup action | Verify |
|---|
| Bearing noise increases | reduce load and inspect bearing | swap with spare unit | noise/vibration returns baseline |
| Overheating trend appears | check airflow and lubrication | derate runtime cycle | temperature within normal range |
| Belt slippage observed | retension and inspect pulleys | replace belt and align drive | slip eliminated under load |
| Unexpected shutdown | follow fault tree before restart | manual bypass only if safe | root cause recorded |
Common Mistakes and Fixes
- Mistake: reactive-only maintenance. Fix: preventive schedule discipline.
- Mistake: no trend data. Fix: log temps, vibration, runtime.
- Mistake: non-standard spare parts. Fix: approved parts list.
- Mistake: rushed restart after fault. Fix: mandatory root cause check.
Scenario Drills
Drill 1: Sudden Overheat Event
- Simulate thermal alarm trigger.
- Run isolate, inspect, cool-down sequence.
- Apply corrective service.
- Goal: safe recovery without damage.
Drill 2: Spare Part Substitution
- Simulate missing primary component.
- Use approved alternate and recalibrate.
- Validate under controlled load.
- Goal: restore function with full traceability.
Printable Checklist
- [ ] Asset and criticality list current
- [ ] Daily checks completed
- [ ] Service intervals tracked
- [ ] Trend data logged
- [ ] Spare inventory verified
- [ ] Fault investigations documented
- [ ] Restart approval completed
Safety note: bypassing interlocks to save time usually creates larger failures and injury risk.
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