How to Maintain Machines and Equipment That Are Rarely Operated

How to Maintain Machines and Equipment That Are Rarely Operated
Treatment for equipment that is not operating for a long time is an effort to prevent damage from occurring because the equipment stops operating for a long-time including heating, lubricating and sterilizing. Examples of damage include corrosive, dirty / damp / sticky and damage caused by the inside of the equipment being a nest for rats, cockroaches, beetles, ants and snakes.

The reason the equipment has not been operated for a long time is
  • Quiet order
  • The company is being frozen by the government due to company violation provisions.
  • Company permits have expired.
  • A natural disaster caused the factory to stop production pending infrastructure development.
Who is responsible for heating, lubricating and sterilizing while many workers have been laid off because there is no production process yet?

All workers are at home waiting for the recovery of factory conditions while all maintenance continues to work and is responsible for heating, lubricating and sterilizing.

Why are all the maintenance still working?

There is a reduction in maintenance work in the form of equipment repairs but at the same time additional maintenance work appears in the form of maintenance of equipment that has not been operated for a long-time including heating, lubricating and sterilizing.
  1. Heating of production machines, heavy equipment and transport vehicles
  2. Lubrication of metal-based non-machine equipment such as spare parts and machine/equipment support
  3. Sterilization prevents or expels wild animals from nesting in equipment such as rats, cockroaches, ants, beetles and dangerous snakes.
1. Heating Treatment

Includes maintenance of production machine warm-up, heavy equipment and transport vehicles. Implementation of heating maintenance is part of a planned maintenance work program (preventive maintenance).

Instructions for the implementation of heating maintenance for this equipment should be separated from SOP for periodic maintenance or SOP for preventive maintenance and made new as SOP for heating maintenance for production machines or SOP for heating maintenance for heavy equipment and transport vehicles.

Production machine

Heating maintenance for production machines and utility machines is carried out every day. Warm-up time is about 10 minutes. Before starting to warm up the production machine, do a cleaning on the production machine or if necessary, spray it with portable compressor air in areas hard to reach by hand during the cleaning.

Also make sure the condition of the electrical panel is clean. Make sure that the production machine is not undergoing unfinished repairs. Perform production machine start-up steps according to the work instruction guide or SOP for the operation of the production machine in question.

The operation of this production machine is without a load, if it is required to use a load then use a load outside the production process and according to its capacity.

Monitor abnormal conditions such as rough sounds, substandard parameters, engine speed and others depending on the machine's standards.

After about 10 minutes, do the process of shutting down this production machine based on the SOP for the operation of the production machine in question. Record the hour meter before and after warming up the production machine along with the time the production machine is warming up

If an abnormal condition is found, repair it immediately and report it to the head of maintenance directly or through a report.

Heavy equipment

Examples of heavy equipment include hydraulic excavators, wheel loaders, forklifts and hoist cranes. The machine warm-up time is approximately 10 minutes each day.

Clean the outside of the body but don't use wind to avoid dust being pushed into deeper parts such as entering the radiator and engine areas. Cleaning using compressed air only for the arm guard radiator and arm guard engine with first removed, cleaned in a separate place.

Cleaning the air filter is cleaned manually until the dirt drops. Furthermore, you can spray compressed air with a very low pressure and the direction of spraying is from inside the air filter to the outside.

Turn on the engine, move all hydraulic and mechanical systems, if there is an abnormal sound, add grease. Check engine oil level and hydraulic oil level. After 10 minutes of warming up, turn off the engine again.

Carrier wagon

Factory transport vehicles are vehicles that transport finished goods to customers, take main materials from suppliers if suppliers have not provided vehicles and transport goods between warehouses.

Examples of transport vehicles: engkel, dump trucks, long tanks, wing boxes and container trailers. Usually, the industry does not have many transportation vehicles, except for certain industries, such as the B3 waste processing industry, which will have hundreds of transport vehicles.

The duration of the warm-up is about 10 minutes every day.

This transport vehicle will be removed from the battery / battery to avoid short circuits but with the engine warming up every day, removing the battery is not necessary.

Turn on the engine, move all functions including the hydraulic dump truck function. After 10 minutes of warming up, turn off the engine again.

The heating maintenance above does not apply to the heating of generators and stored mobile assets because the heating of generators and the heating of stored mobile assets is part of the SOP for periodic maintenance of generators and the SOP for periodic maintenance of these stored assets which require heating maintenance which is not affected by the operation of the production process.

2. Lubrication Treatment

Lubrication treatment is applied to metal-based non-machine equipment such as production machine spare parts and support.

Metal spare parts include new spare parts in the spare parts warehouse and used spare parts that can still be used again in the mechanical area. Both must be given lubrication by coating the surface using grease to prevent corrosive.

It is enough to provide this lubrication 1 time until the factory condition recovers so that after being coated with grease it is then stored neatly if it needs to be wrapped first using stretch film.

3. Sterilization Treatment

Sterilization treatment to expel wild animals nesting in equipment such as rats, cockroaches, ants and snakes.

Sterilization can use an electronic animal repellent device, but you should pay attention to the impact of using this tool, is it dangerous for human safety because the method of operation of this tool uses certain sound frequencies and has the potential to hurt the eardrum or cause miscarriage.

It is recommended to turn on this animal repellent only at night when leaving work and turn it off when returning to work the next morning.
Umar A
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